description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to drilling fluid compositions and to methods for drilling a subterranean wellbore or borehole. More particularly, this invention relates to compositions and methods for removing drill cuttings from boreholes and also for separating the cuttings from drilling fluids.
[0003] 2. Description of Relevant Art
[0004] Rotary drilling methods employing drilling apparatus having a drill bit and drill stem have long been used to drill wellbores or boreholes in subterranean formations. Drilling fluids or muds are commonly circulated in the well during such drilling to serve a number of functions, including cooling and lubricating the drilling apparatus, counterbalancing the subterranean formation pressure encountered, and removing drill cuttings from the formation out of the wellbore. In removing drill cuttings from the well, drilling fluids suspend the cuttings and carry them to the surface for removal from the well.
[0005] Drilling deviated and horizontal wells have become increasingly common in the oil and gas industry. In drilling such wells, gravity causes deposits of drill cuttings, the sizes of which range from microns in diameter to that of common pebbles, and especially fines or smaller sized cuttings, to build up along the lower or bottom side of the wellbore. Such deposits are commonly called “cuttings beds.” As used herein, the term “deviated” with respect to wells shall be understood to include any well at sufficient angle or deviation off of vertical that cuttings beds tend to form during the drilling operation. “Deviated” wells shall be understood to include without limitation “angled,” “high-angled,” “oval,” “eccentric,” “directional” and “horizontal” wells, as those terms are commonly used in the oil and gas industry. The terms “well,” “wellbore” and “borehole” are synonymous as used herein.
[0006] The viscosity of a drilling fluid is commonly increased to enhance the fluid's drill cuttings-transport capability. However, pumping high-viscosity fluids can be disadvantageous to the economics of oil well drilling by effecting high friction pressure, requiring higher horsepower pumping equipment and subsequent higher fuel expenditure. Higher drilling fluid viscosity is advantageous only in the annular space between drill pipe and borehole, where drill cuttings are located and from which they need to be removed. In other locations within the well during drilling, primarily inside the drillpipe and flow channels within the bit, lower viscosity is preferred for the drilling mud so as to minimize frictional pressure loss. The narrower flow channels inside the drillpipe and drill bit cause the drilling fluid to undergo a higher shear rate, which also increases frictional pressure loss. To counteract this undesirable occurrence, drilling fluids currently in common use are referred to as “shear-thinning” fluids because they have been designed to have a higher viscosity when at lower shear rate and lower viscosity in higher shear rate conditions. This serves, to some extent, to satisfy both the need for higher viscosity in the wellbore annulus and lower viscosity inside the drill pipe and drill bit. However, the current state of the art in drilling fluids design allows for only a limited degree of control of the variance in fluid viscosity between these various locations in the well being drilled.
[0007] Cleaning (i.e., removing drill cuttings from) a deviated well, particularly drilled at a high angle, can be difficult. Limited pump rate, limited drilling fluid density, eccentricity of the drill pipe, sharp build rates, and oval-shaped wellbores can all contribute to inadequate hole cleaning. In turn, inadequate hole cleaning can lead to cuttings beds build-up in the wellbore, because commonly used drilling fluids are often unable to sufficiently remove cuttings from such cuttings beds while circulating through the wellbore.
[0008] Buildup of cuttings beds can lead to undesirable friction and possibly to sticking of the drill string. Such buildup is especially a problem in Extended Reach Drilling, in which the majority of the length of the well is deviated from vertical by more than 40 degrees.
[0009] Well treatments or circulation of fluids specially formulated to remove these cuttings beds are periodically necessary to prevent buildup to the degree that the cuttings or fines interfere with the drilling apparatus or otherwise with the drilling operation. Two commonly used types of treatment fluids that have been applied with limited success are highly viscous fluids, having greater viscosity than the drilling fluids being used in the drilling operation, and lower viscosity fluids, having less viscosity than the drilling fluids being used in the drilling operations. Commonly, the drilling operation must be stopped while such treatment fluids are swept through the wellbore to remove the fines. It is desired, but difficult, to prevent intermixing of these treatment fluids with the drilling fluid. Such occurrences can be problematic in that they may alter the physical properties, such as density, of the drilling fluid.
[0010] A new method taught in U.S. Pat. No. 6,290,001, issued Sep. 18, 2001 to West et al., enables a sweep without stopping the drilling operation. In that method, a sweep material is added to the wellbore drilling fluid, either directly or in a carrier fluid compatible with the drilling fluid. The sweep material is circulated in the well, where it dislodges, suspends or pushes drill cuttings, especially fines and smaller sized cuttings deposited on the lower side of the wellbore or in cuttings beds, to the surface of the well. The sweep material is then removed from the drilling fluid, preferably by sieving or screening, so the drilling fluid may be returned to the wellbore without significant change in density. The sweep material comprises a weight material, such as barium sulfate, that has been ground and sieved to a specific grind size sufficiently small to be suspendable in the drilling fluid and generally harmless to the fluid pumping apparatus but sufficiently large to be screened out of the drilling fluid, preferably by the principal shale shaker for the drilling operation.
[0011] There continues to be a need, however, for more methods and materials for removing drill cuttings from wellbores.
SUMMARY OF THE INVENTION
[0012] The method of the present invention employs a drilling fluid whose viscosity increases after the fluid passes through the drill bit nozzles in the borehole and decreases after the fluid returns to the well surface. This viscosity change is effected by using a drilling fluid containing a polymer that can be caused to crosslink (which increases the fluid's viscosity) downhole. The crosslinking can be reversed after the fluid returns to the well surface to facilitate ease of removal of drill cuttings and recycling of the drilling fluid.
[0013] Such delayed and reversible crosslinking may be effected in a number of ways. A preferred approach is to provide a drilling fluid comprising an aqueous base, a crosslinkable polymer, and a crosslinking agent. A crosslink activator encapsulated in an encapsulant is provided in the drilling fluid. The crosslink activator may be the crosslinking agent or it may be an agent that facilitates crosslinking of the polymer by the crosslinking agent, such as a pH adjusting compound. The encapsulant comprises a material or composition that can maintain its integrity and contain the crosslink activator apart from the polymer when introduced into the fluid before injection into the well but which breaks up or dissolves in the wellbore releasing the crosslink activator into the drilling fluid. The breaking up or dissolving of the encapsulant may be due to shearing caused by passing the fluid through the drill nozzles or may be due to increased temperature in the wellbore. Other suitable means for breaking up or dissolving of the encapsulant may alternatively be used. Once released into the drilling fluid, the crosslink activator can effect the crosslinking of the polymer. The drilling fluid containing the crosslinking and crosslinked polymer is circulated in the wellbore where it entrains drill cuttings.
[0014] When the drilling fluid, which contains drill cuttings, reaches the well surface, the crosslinking is reversed (which reduces the fluid's viscosity). The drill cuttings are then removed from the fluid and additional encapsulated crosslinking activator is added back to the fluid (along with any other appropriate or needed additives, such as weighting agents to provide or maintain desired density, to complete the drilling fluid) for recirculation of the fluid in the wellbore.
[0015] An advantage of this method is that highly viscous fluids may be used for removing drill cuttings from the well without forcing such viscous fluids through the drill bit nozzles and hence without taxing pumping equipment. Further, such viscous fluids may be used as the drilling fluid, without altering the density of the drilling fluid, and without stopping the drilling for a sweep of the wellbore with viscous fluid to remove drill cuttings.
[0016] Another advantage of the method of the invention is that it allows flexibility during the drilling operation itself. The viscosity of the fluid may be adjusted as frequently as each cycle of drilling fluid in the wellbore. Although such frequency is not likely to be needed, it demonstrates the flexibility of the method. Thus, as the fluid rheology and other drilling conditions and subterranean formation characteristics (i.e., pore pressure, rock types, oil/gas/water saturation, etc.) are being monitored real-time during drilling, and if such formation characteristics and drilling conditions change, the fluid viscosity may be changed according to the method of the invention to quickly adapt to such changes in the formation. The fluid viscosity may be quickly changed by changing the amount or kind of crosslink activator being added back into the fluid at the well surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention provides a method for drilling a borehole in a subterranean formation employing a drilling fluid comprising a polymer viscosifier and an encapsulated crosslink activator for crosslinking the polymer viscosifier. The crosslinked polymer provides the fluid with viscosity and suspension capability to enable the fluid to suspend (or to better suspend) drill cuttings for transport out of the borehole. The polymer does not become fully crosslinked or provide the desired viscosification for the drilling fluid until after the fluid enters the borehole. Preferably, the crosslinking does not begin until after the fluid passes through the drill bit being used to drill the borehole. Once the fluid has reached the desired location in the borehole, however, the crosslinking should be relatively rapid to enable the fluid to quickly entrain drill cuttings for transport to the well surface.
[0018] A key element of the invention is that the crosslinking of the polymer is reversible, preferably easily and quickly, such that the viscosity of the fluid can be reduced when the fluid cycles or circulates back to the well surface for ease of removal of the drill cuttings and for preparation for return to the wellbore for recirculation.
[0019] Any drilling fluid containing polymer capable of reversibly crosslinking and consequent viscosity changes may be used in the present invention. Generally, the drilling fluids for use in this invention are comprised of water, depolymerized polymer (preferably fully hydrated), a pH-adjusting compound used to control the pH of the drilling fluid to an optimum level for crosslinking, and a crosslinking agent. In at least one embodiment of the invention, the crosslinking agent is encapsulated to delay crosslinking the depolymerized polymer. In at least one alternative embodiment of the invention, the pH adjusting compound used to control the pH of the drilling fluid to an optimum level for crosslinking is encapsulated to delay crosslinking the depolymerized polymer. Preferably the polymer used in the present invention will be a depolymerized polysaccharide polymer, and most preferably the polymer will be a depolymerized hydroxypropylguar.
[0020] Typically, the depolymerized polymer used in the invention will be maintained in concentrated form until the drilling fluid is prepared for use in drilling a wellbore. Such concentrate is preferably fully hydrated and can be stored for long periods of time prior to use. When the drilling fluid concentrate is fully hydrated, time for hydration is not needed when the concentrate is later mixed with additional water and any other desired additives to form a drilling fluid and the drilling fluid may be more quickly prepared. When the concentrate is mixed with water, preferably continuously, along with any additional additives required or desired, for producing the drilling fluid, the water is mixed with the concentrate in a water-to-concentrate ratio ranging from about 4:1 to about 20:1, depending upon the final viscosity desired in the drilling fluid. The water used may be fresh water, unsaturated salt water including brines or seawater, or saturated salt water. As used herein particularly with respect to preparation of the polymer or the drilling fluid for use in the present invention, the term “water” shall be understood to be any of these types of water. Such mixing of the drilling fluid concentrate with water and other additives can be done quickly with little delay in readying the resultant drilling fluid for pumping into the drill pipe. Consequently, the properties of the drilling fluid can be periodically or continuously changed during the time that drilling and pumping of the drilling fluid takes place.
[0021] A fully hydrated depolymerized polymer suitable for preferred use in the invention may be manufactured by various means known to those skilled in the art. For example, the polymer may be manufactured by forming a hydratable polymer having a relatively high molecular weight as a result of derivatization of a polysaccharide and then subjecting it to extensive depolymerization whereby the polymer backbone is divided into short chain polymer segments. The manufacture of such polymers can be performed by, for example, Rhodia Inc. of Cranberry, N.J. using well known derivatization and depolymerization techniques.
[0022] The hydratable polymer used for forming the short chain segments may be any polysaccharide and is preferably a guar derivative polymer selected from the group consisting of hydroxypropylguar, carboxymethylhydroxypropylguar, carboxymethylguar, hydroxyethyl cellulose, carboxymethyl cellulose, carboxymethylhydroxyethyl cellulose, and the like. Of these, depolymerized hydroxypropylguar is preferred. Polyacrylamides and/or polyacrylonitriles may also be used instead of or in addition to polysaccharides. The depolymerized polymer should have an average molecular weight in the range of from about 25,000 to about 400,000 and preferably has an average molecular weight in the range of from about 50,000 to about 250,000. If desired for purposes of transportation, storage or otherwise, the depolymerized polymer may be stored in dry form, and, when needed, may be rehydrated to form the drilling fluid concentrate. Fully hydrated depolymerized polymer is preferably admixed with water in an amount in excess of about 8% by weight of the drilling fluid concentrate to form the drilling fluid concentrate. Preferably, the polymer is present in an amount of from about 8% to about 25% or more by weight and most preferably from about 8% to about 15% by weight of the drilling fluid concentrate. The viscosity of the drilling fluid concentrate generally may be in the range of from about 1,000 to in excess of about 35,000 cps as determined with a Brookfield DV II+RV spring viscometer manufactured by Brookfield Engineering Laboratories in Middleboro, Mass.
[0023] In some instances it may be desirable to add a dispersing agent to the polymer. This agent helps to disperse depolymerized hydratable polymer when it has been stored in a dry form, and also facilitates rehydration of such polymer in water. Dispersing agents found to be particularly suitable include light hydrocarbon oils such as polyethylene glycol, diesel oil, kerosene, olefins and the like. Of these, polyethylene glycol is preferred. When a dispersing agent is used, it is included with the polymer in an amount ranging from less than about 5% to about 60% or more by weight of the polymer.
[0024] A variety of other additives may be included in a drilling fluid concentrate at the time of its manufacture for use in this invention. In at least one embodiment, such additives may include pH-adjusting compounds to control the pH of the drilling fluid to achieve an optimum or desired level for crosslinking when mixed with additional water to form a drilling fluid. Examples of such compounds which may be used include, but are not limited to, sodium hydroxide, potassium hydroxide, lithium hydroxide, various carbonates or any other commonly used pH control agents which does not adversely react with the polymer to obstruct its use. Of these, sodium hydroxide is preferred. When used or added to the drilling fluid concentrate, the pH adjusting compound is included in the concentrate in an amount ranging from about 0.5% to about 10% by weight of the water therein.
[0025] A pH buffer may also be included in the concentrate. Examples of buffers which may be used include, but are not limited to, sodium carbonate, potassium carbonate, sodium bicarbonate, potassium bicarbonate, sodium or potassium diacetate, sodium or potassium phosphate, sodium or potassium hydrogen phosphate, sodium or potassium dihydrogen phosphate and the like. When used, the buffer is included in the concentrate in an amount ranging from about 0.5% to about 10% by weight of the water therein.
[0026] Another additive which may be included in the drilling fluid concentrate is a surfactant for preventing the formation of emulsions between the fluid which is formed with the concentrate and subterranean formation fluids. Examples of surfactants which may be used include, but are not limited to alkyl sulfonates, alkyl aryl sulfonates including alkyl benzyl sulfonates such as salts of dodecylbenzene sulfonic acid, alkyl trimethylammonium chloride, branched alkyl ethoxylated alcohols, phenol-formaldehyde nonionic resin blends, cocobetaines, dioctyl sodium sulfosuccinate, imidazolines, alpha olefin sulfonates, linear alkyl ethoxylated alcohols, trialkyl benzylammonium chloride and the like. Of these, salts of dodecylbenzene sulfonic acids are preferred. When used, the surfactant is included in the concentrate in an amount ranging from about 0.01% to about 10% by weight of the water in the drilling fluid.
[0027] Another additive which may be included in the drilling fluid concentrate is a clay stabilizer. Examples of clay stabilizers which may be used include, but are not limited to, potassium chloride, sodium chloride, ammonium chloride, tetramethyl ammonium chloride, and the like. Of these, potassium chloride and tetramethyl ammonium chloride are preferred. When used, the clay stabilizer is included in the concentrate in an amount ranging from about 2% to about 20% by weight of the water therein.
[0028] Any of the additives to the drilling fluid concentrate discussed above may be alternatively added (or even additionally added) to the drilling fluid itself. The drilling fluid is prepared from the drilling fluid concentrate by adding water to the concentrate and by adding other additives needed to complete the fluid as a drilling fluid, particularly if such additives are not in the concentrate. For example, weighting agents such as, for example, calcium carbonate, barite, hematite, strontium sulfate, and amorphous silica, will likely be added to the fluid to increase the density of the fluid to the weight needed for the particular subterranean formation and use of the fluid.
[0029] In order to increase the viscosity of the drilling fluid formed with or from the drilling fluid concentrate, a crosslinking agent is mixed with the water and drilling fluid concentrate and/or with the drilling fluid. In at least one embodiment of the invention, such mixing preferably occurs downhole. The crosslinked short chain segments of the fully hydrated depolymerized polymer are crosslinked by the crosslinking agent thereby producing a viscous drilling fluid.
[0030] The crosslinked drilling fluids of the present invention produce filter cake containing low molecular weight polymer segments which make the filter cake easily removable. When crosslinkers discussed below are used, the crosslinks are broken simply by lowering the pH to a level below about 9. In this pH range, the drilling fluid is generally not crosslinked and yet the acetal linkages which form the crosslinking sites are generally stable and can be recrosslinked. This feature allows the drilling fluid to be recovered from drilling the borehole and reused rather than having to be disposed of or discarded. This recycling of the drilling fluid reduces waste-disposal costs and avoids or alleviates environmental concerns that may become associated with waste disposal. The recovery and reuse of the drilling fluids of this invention makes them much more economical to use than conventional prior-art drilling fluids.
[0031] Examples of preferred crosslinking agents (which may be used in the drilling fluid to effect the crosslinking as described above) include, but are not limited to: boron compounds such as, for example, boric acid, disodium octaborate tetrahydrate, sodium diborate and pentaborates, ulexite and colemanite; compounds which can supply zirconium IV ions such as, for example, zirconium lactate, zirconium lactate triethanolamine, zirconium carbonate, ziroconium acetylacetonate and zirconium diisopropylamine lactate; compounds that can supply titanium IV ions such as, for example, titanium ammonium lactate, titanium triethanolamine, titanium acetylacetonate; aluminum compounds such as aluminum lactate or aluminum citrate; or compounds that can supply antimony ions. Of these, a borate compound is the most preferred. The exact type and amount of crosslinking agent or agents used depends upon the specific depolymerized polymer to be crosslinked, temperature, fluid loss, and other formation conditions and factors known to those skilled in the art. The crosslinking agent used in the drilling fluid ranges in concentration from about 50 ppm to about 5000 ppm of active crosslinker.
[0032] According to the method of the invention, crosslink activators, which are either the crosslinking agents or pH-adjusting compounds, are encapsulated with a material that preferably helps to delay their interaction with the crosslinkable polymer in the drilling fluid, such as, for example, a material that is insoluble or only slightly soluble in an aqueous environment. This delay mechanism allows the drilling fluid to become viscosified or crosslinked at desirable times and locations. U.S. Pat. Nos. 5,591,700 to Harris, et al., issued Jan. 7, 1997, 5,604,186 to Hunt et al., issued Feb. 18, 1997, 6,187,720 to Acker et al., issued Feb. 13, 2001, 6,209,646 to Reddy et al, issued Apr. 3, 2001, and 6,357,527 to Norman et al, issued Mar. 19, 2002, the entire disclosures all of which are incorporated herein by reference, provide various methods and means for encapsulating chemical additives to delay their interactions with the fluids in which they are being mixed. These methods and means provide examples that may be applied in the present invention for encapsulating the crosslink activators. Typically, the crosslink activators are released or unencapsulated or the encapsulation is destroyed or dissolved at warmer temperatures encountered in a subterranean formation or when subjected to shear as when passing through the nozzles of a drill bit.
[0033] When the preferred crosslinking agent being used is a borate compound, the pH-adjusting compound is used to elevate the pH of the drilling fluid to above about 9. At that pH, the borate compound crosslinking agent crosslinks the short-chain hydrated polymer segments. When the pH of the crosslinked drilling fluid falls below about 9 , the crosslinked sites are no longer crosslinked.
[0034] In order to cause or help the drilling fluid to revert (preferably completely) to a thin or less viscous fluid in a short period of time, a delinker capable of lowering the pH of the drilling fluid may be included in the drilling fluid initially or may more preferably be added to the drilling fluid at the well surface when the fluid returns to the surface after circulation in the wellbore. If added initially, the delinker should be a delayed delinker and preferably should be encapsulated so as not to interfere with the crosslinking in the wellbore. The action of such delinker should preferably be delayed until the fluid has been circulated in the borehole and returned to the well surface. In one alternative embodiment, a delayed delinker and/or delayed breaker is used where the delay is so long as to not delink or break until some time after the fluid has circulated and deposited some of such fluid on the wellbore wall as filtercake. The delayed delinker or delayed breaker may then act to break down the filter cake to help bond cement to the formation wall (in a cementing operation) or to minimize the obstruction of a production surface area after the zone has been gravel packed. In this particular alternative embodiment, however, as with other embodiments, the delinkers or breakers that are not delayed may be added to the drilling fluid when it circulates back to the well surface to enhance or hasten the reversal of the crosslinking to prepare the fluid for recycling back into the borehole.
[0035] Examples of delinkers which may be used include, but are not limited to, various lactones, hydrolyzable esters, and acids. Of these, the hydrolyzable esters are preferred. Examples of delayed delinkers include these same delinkers when put in encapsulated form, and also slowly soluble acid generating compounds. The delinker may be included in or added to the drilling fluid in an amount ranging from about 0% to about 5% by weight of the water therein. Alternatively, any of the conventionally used breakers employed with metal ion crosslinkers may be used in addition to or instead of delinkers. Examples of such breakers include oxidizers such as sodium persulfate, potassium persulfate, magnesium peroxide, ammonium persulfate, and the like. Enzyme breakers that may be employed include alpha and beta amylases, amyloglucosidase, invertase, maltase, cellulase and hemicellulase. The specific breaker and/or delinker used, whether or not either or both are encapsulated, as well as the amount thereof employed will depend upon the breaktime desired, the nature of the polymer and crosslinking agent, formation characteristics and conditions, and other factors in keeping with the purposes of the invention.
[0036] As previously discussed, after the fluid has been uncrosslinked and the drill cuttings removed, the fluid may be prepared for recycling back into the wellbore. Such preparation will likely include adding crosslink activator back into the fluid and adding any additional crosslinking agent needed (if different from the crosslink activator). Other additives such as additional weighting agent may be needed or desired and added as well.
[0037] Preferably, the drilling fluid according to the invention is prepared by metering the drilling fluid concentrate or used drilling fluid that has been uncrosslinked and had drill cuttings removed into a blender wherein it is mixed with additional water and/or additives which also may be metered into the blender or otherwise added to the fluid. The mixture may then be pumped, preferably simultaneously, out of the blender and into the drillpipe, wherein it proceeds downhole. The time period, starting from when the metering, mixing and pumping process starts to when the formed drilling fluid reaches the drill bit and subterranean formation to be drilled, is usually and preferably a time period of only several minutes. This ease and speed of preparation allows changes in the properties of the drilling fluid to be made on the surface as required during the time the drilling fluid is being pumped. For example, in a drilling procedure carried out in a subterranean formation which involves layers or zones of shale and sandstone, changes may be made to the drilling fluid in response to continuously monitored downhole parameters to achieve desired borehole stability, or to minimize damage to the formation wall, or to minimize fluid loss or invasion. Fluid loss control capability, viscosity, pH, salinity, to name a few, are some properties of the drilling fluid that may be continuously measured on the surface and changed as required to achieve optimum downhole treatment results in real time.
[0038] In an alternative embodiment of the invention, the principles of the invention may be used for a viscous sweep instead of for a drilling fluid. In this application, more crosslinkable polymer and/or more crosslinker may be used so that the fluid can be made more viscous than is typically preferred for a drilling fluid, although the fluid should not be capable of becoming so viscous as to lose its ability to be circulated in the borehole. The fluid may also have more suspension agents. As with the embodiments for the drilling fluid, the crosslink activator is encapsulated so that the polymer does not crosslink or does not fully crosslink until in the borehole. The fluid is then circulated in the borehole to entrain drill cuttings, and particularly drill cuttings that may have settled into cuttings beds or otherwise not been removed by the drilling fluid in the routine drilling operation. The sweep fluid is then brought to the well surface with the cuttings for removal. As with the drilling fluid embodiments of the invention, at the well surface, the viscosity of the drilling fluid is reduced for ease of removal of the drill cuttings. Such reduction in viscosity may be obtained by delinkers and/or breakers as used in the drilling fluid embodiments of the invention. Encapsulated crosslink activators may then be added back to the fluid for repeat of the treatment or viscous sweep. As with the drilling fluid embodiments, when the encapsulated crosslink activator contains a base for increasing the pH of the drilling fluid to crosslinking conditions, the sweep fluid should contain a crosslinker that causes crosslinkable polymer in the fluid to crosslink at that pH. When the encapsulated crosslink activator contains a crosslinker, the sweep fluid should contain a polymer in the fluid that is crosslinkable by that crosslinker and the sweep fluid should be maintained at a pH conducive to such crosslinking when crosslinking is desired, as when the fluid is in the borehole. An advantage of the present invention over prior art viscous sweeps is the ability of the fluid of the present invention to be quickly prepared for recycling or reuse in the borehole.
[0039] The foregoing description of the invention is intended to be a description of preferred embodiments. Various changes in the details of the described composition and methods may be made without departing from the intended scope of this invention as defined by the appended claims. | A method is disclosed for drilling a wellbore employing a drilling fluid providing the advantages of easy pumpability of a low viscosity fluid with the drill cuttings suspension capability of a highly viscous fluid. The viscosity of the fluid is also easily and quickly adjustable so that the fluid rheology may be adapted during drilling as the subterranean conditions change. These advantages are obtained by including in said fluid a reversibly crosslinkable polymer and an encapsulated crosslink activator. The crosslink activator causes crosslinking after the fluid is in the wellbore. The crosslinking is reversed at the well surface to reduce the viscosity of the fluid to enable the drill cuttings to be easily removed. Crosslink activator is added back to the fluid and the fluid is returned to the borehole. The amount of crosslink activator and/or crosslinkable polymer may be adjusted in the fluid to change the fluid rheology to conform the fluid to changes in the well conditions as monitored real time. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to plasticized and stablized poly (vinyl chloride) ["PVC"] compositions, especially those PVC compositions destined for the production of transparent molded articles.
2. Description of the Prior Art
A great number of reference articles relate to PVC-based compositions, plasticized and stabilized against thermal degradation or decomposition caused by either the actual on-stream processing of the composition, or upon subsequent high-temperature utilization.
It is known, for example, according to U.S. Pat. No. 2,711,401, that the use of a mixture of polyol and organic salts of polyvalent metals enables retardation of the yellowing of molded articles subjected to heat.
Furthermore, according to U.S. Pats. Nos. 3,003,998, 3,003,999 and 3,004,000, non-toxic stabilizers have been found which can be used for the packaging of food products, and which are based on a mixture of fatty acid salts of magnesium, zinc or calcium with a polyol. However, the transparency demanded for certain applications canot be obtained with these mixtures.
French Pat. No. 1,435,882 proposes the association of an organic salt of an alkali metal and a ketoacetic ester or dehydroacetic acid. However, the resulting stabilization is far from satisfactory.
DESCRIPTION OF THE INVENTION
The present invention relates to compositions which are devoid of toxic constituents and which can be processed into transparent molded articles which are without coloration, and the initial color of which is not appreciably deleteriously affected by heat treatment of 180° C. for more than an hour.
These compositions according to the invention are characterized in that they contain, per 100 parts by weight of the PVC:
[a] 5 to 120 parts by weight of a conventional PVC plasticizer;
[B] 0.1 TO 5 PARTS BY WEIGHT OF A PAIR OF ORGANIC ACID SALTS OF CALCIUM AND OF ZINC;
[c] 0.03 to 1 part by weight of a linear polyol having at least four hydroxyl functions, at least one of which being a primary alcohol function; and
[d] 0.05 to 5 parts by weight of an organic compound having the structural formula:
R.sub.1 --CO--CHR.sub.2 --CO--R.sub.3 (I)
wherein R 1 and R 3 , which can be identical or different, represent:
A linear or branched chain alkyl or alkenyl radical having at least one and up to 36 carbon atoms,
An aralkyl radical having from 7 to 36 carbon atoms, and
An aryl or cycloaliphatic radical having fewer than 14 carbon atoms, the cycloaliphatic radicals optionally comprising carbon-to-carbon unsaturation or double bonds.
The foregoing radicals either may or may not be substituted, and, when substituted, suitable substituents comprise, for example, halogen atoms, or, in the case of the aryl or cycloaliphatic radicals, methyl or ethyl radicals; they too can be modified by the presence of one or more of the linkages --O--, ##STR1## or --CO--, in the aliphatic chain; and together same can also represent a divalent alkylene radical of 2 to 5 carbon atoms, optionally containing a bridging oxygen or nitrogen atom.
R 2 represents:
a hydrogen atom,
an alkyl or alkenyl radical, having at least one and up to 36 carbon atoms, which can contain one or more of the linkages --O--, ##STR2## or --CO--, a radical of the formula --CO--R 4 , R 4 representing an alkyl radical having from 1 to 36 carbon atoms, or an aryl radical having from 6 to 10 carbon atoms, or
a radical of the formula ##STR3## R 5 representing an alkyl radical having from 1 to 6 carbon atoms, and R 1 and R 3 being as above.
The radicals represented by the symbols R 1 , R 2 and R 3 are, in addition, such that:
for R 1 and R 3 , the carbon atom bonded to the respective carbonyl function of the compound (I) is free from ethylenic or carbonyl unsaturation;
for R 1 or R 3 , the carbon atom bonded to the respective carbonyl function does not comprise a moiety which includes aromatic unsaturation.
One of the radicals R 1 or R 3 can represent a hydrogen atom.
R 1 and R 2 together can represent a divalent radical selected from among the following:
a linear or branched alkylene or alkenylene radical, having up to 36 carbon atoms,
an aralkylene radical having from 7 to 36 carbon atoms, and
an arylene or cycloalkylene radical having fewer than 14 carbon atoms, the cycloaliphatic radicals optionally comprising carbon-to-carbon unsaturation or double bonds.
These latter radicals too either may or may not be substituted, and, when substituted, suitable substituents comprise, for example, halogen atoms, or, in the case of the aryl or cycloaliphatic radicals, methyl or ethyl radicals.
The radicals heretofore enumerated can also be modified by the presence, in any given aliphatic chain, of one or more of the linkages: ##STR4##
The stabilizing systems above identified can additionally comprise an epoxidized compound, such as, for example, epoxidized soya-bean oil, in a proportion of between 0 and about 8% by weight relative to the polymer. The addition of this type of compound further improves the heat stability.
By "PVC-based compositions", or the like, there is intended essentially those compositions in which the polymer is a homopolymer of vinyl chloride, and one preferably obtained via a bulk or suspension polymerization process.
However, polymers obtained by other processes, or containing minor fractions, for example, below 20% by weight, of other ethylenically unsaturated monomers copolymerized with the vinyl chloride, are also within the ambit of the invention. Comonomers of this type comprise, for example, vinylidene chloride, vinyl or maleic esters, or ethylene or other olefin comonomers.
By "conventional" PVC plasticizers there is intended all of those plasticizers which are normally and typically used to plasticize PVC. Plasticizers of this type are described in the Encyclopedia of Polymer Science and Technology, Vol. 14, pages 396 to 400, Interscience Publishers (1964). These are essentially phthalates, phosphates, esters of aliphatic diacids or, where appropriate, polyesters.
Four pairs of organic salts of metals are particularly valuable for stabilization according to the invention: calcium or barium salts used conjointly with cadmium or zinc salts, the barium-cadmium pair being considered the most efficient. However, it has also been found that results which are at least equivalent are obtained by substituting the calcium-zinc pair for the barium-cadmium pair in the compositions of the invention. Furthermore, the absence of toxicity of the calcium and zinc salts makes this latter pair of metals the more preferable.
The anions of these salts are preferably selected from among the aliphatic and aromatic organic acids or fatty acids, which either may or may not be saturated or substituted. Among the salts commonly employed there are mentioned as illustrative: acetates, diacetates, stearates, oleates, laurates palmitates, benzoates, hydroxystearates or ethyl-2-hexanoates.
A large number of polyols too have been proposed for increasing the stability of PVC, and particularly those polyols having more than two and fewer than nine hydroxyl group and having a boiling point above 120° C., such as glycol, glycerol, sorbitol and pentaerythritol [U.S. Pat. No. 2,711,401].
French Pat. No. 1,435,882 reflects, especially in the Table 6 thereof, that the combined use of an organic stabilizer, such as a ketoacetic ester, and a polyol, such as mannitol, sorbitol, pentaerythritol, dipentaerythritol or tripentaerythritol, provides but poor heat stabilization of PVC.
It has now been found that a very significant increase in heat stability is obtained by adding to the stabilizing system, consisting of a pair of metal salts and β-diketone compounds, from 0.03 to 1, and preferably from 0.1 to 0.25 parts per 100 parts by weight of PVC, one of the following three polyols: D-xylitol, D-sorbitol and D-mannitol. The selection of suitable amounts of the polyol is crucial and depends in turn on the amount of the β-diketone compound and calcium-zinc pair utilized.
Addition of these polyols does not effect coloration of any molded articles shaped from the subject compositions and considerably prolongs the heat stabilization by preventing yellowing. Furthermore, these polyols are not toxic.
All of the β-diketone compounds satisfying the above definition and parameters are suitable for purposes of this invention, whether used alone or in admixture. Representative of the especially preferred compounds are: benzoylacetone, lauroylbenzoylmethane, myristoylbenzoylmethane, palmitoylbenzoylmethane, stearoylbenzoylmethane, behenoylbenzoylmethane, dilauroylmethane, dimyristoylmethane, dipalmitoylmethane, distearoylmethane, dibehenoylmethane, lauroylmyristoylmethane, lauroylpalmitoylmethane, lauroylstearoylmethane, lauroylbehenoylmethane, myristoylpalmitoylmethane, myristoylstearoylmethane, myristoylbehenoylmethane, palmistoylstearoylmethane, palmitoylbehenoylmethane, stearoylbehenoylmethane, 1-phenyltriacetone-1,3-dione, acetyltetralone, palmitoyltetralone, stearoyltetralone, palmitoylcyclohexanone, stearoylcyclohexanone and (paramethoxybenzoyl)-stearoylmethane. These compounds are utilized in amounts of between about 0.05 and 5% by weight relative to the weight of the PVC and, preferably, between about 0.1 and 1% by weight.
Various adjuvants can be added to the subject compositions, such as, for example, antioxidants, or UV light stabilizers, and additives, such as lubricants, ot facilitate processing. It is advisable to carefully monitor the choice of these additives in order not to risk detracting from heat stability. Thus, it has been established that lubricants containing free hydroxyl groups did not display any detrimental effects with regard to heat stability: compounds such as glycerol monostearate or propylene glycol monostearate are especially preferred.
The preparation of the compositions according to the invention can be carried out by any known process. The different stabilizers can be mixed with the plasticizer, either individually, or after having been admixed and then incorporated into the polymer. All of the usual and typical methods known to this art are suitable for achieving the mixing of the various ingredients. However, the homogenization of the composition can be most advantageously carried out by means of a malaxator or a roll mixer, and it is possible to conduct the operation at a temperature such that the material is fluid, which facilitates the mixing.
The compositions themselves can be processed in accordance with conventional techniques normally employed for working plasticized PVC compositions, for example, by extrusion, injection, calendering, molding, rotational molding, slush molding or deposition on a support, which may or may not be provided with a release surface.
The association of calcium-zinc, a β-ketone compound and sorbitol, mannitol or xylitol exhibits very significant stabilizing activity, which enables one to reduce the quantities employed of these various products. The risks of initial coloration or phenomena detracting from transparency are thus limited. In addition, it is possible to process in the absence of additives commonly used in plasticized PVC formulations, such as, for example, phosphites or epoxidized mixtures of fatty acid esters [epoxidized soya-bean oil]. By judicious choice of the products utilized, it is thus possible to obtain very highly stabilized compositions, which compositions are acceptable for use with foodstuffs.
In order to further illustrate the present invention and the advantages thereof, the following specific examples are given, it being understood that same are intended only as illustrative and in nowise limitative.
EXAMPLES 1 to 6
The following were mixed in a ball mill;
2,000 g of PVC powder, having a viscosity index of 95 [standards specifications NFT 51, 013] obtained by bulk polymerization and sold under the trade name LUCOVYL GB 9,550;
780 g of dioctyl phthalate;
10 g of calcium stearate; and
5 g of zinc stearate.
The mixture was allowed to rotate on the rollers for 15 hours.
The following were charged into six 250 cm 3 powder mills, containing a few porcelain balls:
70 g of the mixture above obtained (A);
0.25 g of stearoylbenzoylmethane;
and, respectively, 0.07, 0.10, 0.15 and 0.20 g of xylitol; 0.10 g of D-sorbitol or 0.1 g of D-mannitol.
The mixture was allowed to rotate on a roller mixer for 15 hours, the homogeneous compositions B, C, D, E, F and G being obtained in this manner.
From these compositions, as well as from the composition A, sheets of 2.5 mm thickness were prepared by means of a calendar heated to 160° C. [contact time at this temperature: 3 minutes].
Out of these sheets, rectangular test-pieces of the dimensions 10 × 20 mm were cut, and which were then placed in a ventilated oven heated to 180° C. for variable periods of time.
The coloration of the different samples were determined according to the Gardner scale with the aid of a Lovibond disc.
The following results were obtained:
TABLE______________________________________ Coloration index after X minutesCompositions 0 7 15 25 35 45 55 65______________________________________A 0 3 8 blackB 0 0 0 1 1 2 6 10C 0 0 0 1 1 2 2 3D 0 0 1 2 3 4 4 5E 0 0 1 2 3 4 4 4F 0 0 0 1 1 1 1 2G 0 0 0 0 1 1 2 2______________________________________
It was found that the addition of 0.5% of stearoyl-benzoylmethane and 0.2% of one of the noted three polyols permits the time of heat treatment at 180° C. [necessary to obtain samples which are only faintly yellow-colored] to be multiplied by about 10.
If the quantity of polyol be increased [compositions D and E], or if the quantity of polyol be too small [composition B], a coloration develops after 30 minutes of heat treatment.
EXAMPLE 7
A composition was prepared which is normally used for obtaining semi-rigid profiles destined for decorative purposes.
The following were placed in a high-speed mixer:
11.245 kg of PVC powder having a viscosity index of 80 [standard specification NFT 51,013] ;
0.104 kg of calcium stearate;
0.039 kg of zinc stearate;
0.026 kg of stearoylbenzoylmethane; and
0.026 kg of sorbitol.
The mixture was rotated for 5 minutes at 500 rpm.
0.949 kg of dioctyl phthalate was then introduced over a 3 minute period. The mixture was rotated for an additional 5 minutes at 500 rpm. The mixing speed was then increased to 1,000 rpm and the mixture was allowed to rotate at this speed for that time necessary for the temperature of the mixture to rise to 115°-120° C., and which was about 15 minutes. A dry powder was obtained which was fed into a single-screw extruder rotating at 50 rpm and having a screw diameter of 40 mm and length of 800 mm. The temperature was regulated so as to achieve the following temperatures: 150° C. at the inlet, 155° C. at the middle of the screw, 160° C. at the end of the screw and 165° C. at the head of the extruder, which was equipped with a die and a system for chopping the strands, issuing from the die, into granules.
Starting with these granules, a sheet of a few millimeters' thickness was made by rolling between cylinders heated to 180° C., and from which small pieces were cut, which were placed into a ventilated oven, heated to 185° C., for variable periods of time.
The time after which the small test piece had become black was recorded: 75 minutes were required.
In addition, the Congo Red test were carried out according to standard specification ISO R 182; this made it possible to determine, under standardized conditions, the time taken by a paper impregnated with Congo Red to change color by the action of the hydrochloric acid released on degradation of the sample at 180° C. A time of 81 minutes was found.
EXAMPLE 8
A composition which is intended for the production of shoes was prepared.
The procedure was as indicated in Example 1 with the following products:
3.9 kg of PVC powder having a viscosity index of 140;
1.95 kg of PVC powder having a viscosity index of 79;
0.078 kg of calcium stearate;
0.039 kg of zinc stearate;
0.039 kg of stearoylbenzoylmethane;
0.026 kg of sorbitol; and
2 kg of dioctyl phthalate.
The temperature in the high speed mixer was not allowed to exceed 105° C. and the temperature of the extruder was 125° C., 130° C., 135° C. and 140° C.
The Congo Red test provided a time of 157 minutes.
While the invention has now been described in terms of preferred embodiments, and exemplified and compared with conventional compositions, the skilled artisan will appreciate that various substitutions, omissions, modifications, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the invention be limited solely by the following claims. | PVC is plasticized and stabilized against the effects of heat by formulating therewith [1] a plasticizer, and minor amounts of [2] a mixed organometallic salt couplet, [3] a polyol, and [4] a β-diketone. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of wood-working. More specifically, the invention comprises a woodworking framework clamp which can be used to fabricate drawers and the like.
[0003] 2. Description of the Related Art
[0004] Clamps are widely used in the fabrication of drawers and in many other woodworking applications. It is often necessary in these applications to hold four members together as a frame as they are fastened together by wood glue, nails, screws, staples, disks, or dowels. This is often accomplished by using a single clamp or combination of clamps to provide force to the assembled frame from four different directions.
[0005] Numerous clamps are used in the prior art to supply force to the sides of a drawer as the members are fastened together. Examples of prior art clamps include those described in U.S. Pat. Nos. 2,619,136; 4,132,396; 2,753,902; and 4,027,866. Although these clamps function to hold a drawer frame together as the members are fastened together, they are cumbersome or inefficient in practice. Many prior art clamps come in multiple pieces which can become separated or lost. Other prior art clamps provide long threaded screws and wing nuts as a means of tightening the clamp around the frame. These threaded-screw clamps often require the user to turn multiple wing nuts for many revolutions until the corner brackets of the clamp can engage the members of the frame. Even more, many of these clamps are ineffective in ensuring a square relationship between the members of the frame when the drawer is clamped therebetween.
[0006] It is therefore the purpose of the present invention to provide a woodworking clamp that overcomes the problems with the prior art clamps and is efficient and easy to use.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention comprises a woodworking clamp that can be used for the fabrication of drawers and the like. The clamp features two parallel clamp rails joined at each end by connecting members. A preferred embodiment of the present invention includes a sliding clamp attached to each rail. The sliding clamps operate in unison, and their movement along to the clamp rail is coordinated by a bracing member which adjoins the two clamps.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1 is a perspective view, showing the preferred embodiment of the present invention
[0009] FIG. 2 is a perspective view, showing the preferred embodiment of the present invention clamped around a drawer.
[0010] FIG. 3 is a perspective view, showing the clamp mechanism.
[0011] FIG. 4 is a top view, showing the clamp bracket.
[0012] FIG. 5 is a perspective view, showing an alternate clamping mechanism.
[0013] FIG. 6 is a perspective view, showing an alternate clamping mechanism.
[0014] FIG. 7 is a perspective view, showing an alternate clamping mechanism.
[0015] FIG. 8A is a perspective view, showing an alternate embodiment of the clamp rail.
[0016] FIG. 8B is a perspective view, showing an alternate embodiment of the clamp rail.
[0017] FIG. 9 is a perspective view, showing an alternate embodiment of the present invention.
[0018] FIG. 10 is a perspective view, showing an alternate embodiment of the present invention.
REFERENCE NUMERALS IN THE DRAWINGS
[0019] 10 drawer clamp
[0020] 12 clamp rail
[0021] 14 connecting member
[0022] 16 sliding clamp
[0023] 18 bracing member
[0024] 20 face plate
[0025] 22 connecting bracket
[0026] 24 drawer
[0027] 26 drawer frame
[0028] 28 drawer base
[0029] 30 handle
[0030] 32 threaded shank
[0031] 34 clamp bracket
[0032] 36 bracing bracket
[0033] 38 non-threaded shank
[0034] 40 orifice
[0035] 42 orifice
[0036] 44 joint
[0037] 46 threaded orifice
[0038] 48 rail orifice
[0039] 50 notches
[0040] 52 ridges
[0041] 54 gripping bracket
[0042] 56 handle
[0043] 58 ratcheting lever
[0044] 60 spring toggle
[0045] 62 screw tightener
DESCRIPTION OF THE INVENTION
[0046] A detailed illustration of the preferred embodiment of the present invention is shown in FIG. 1 . Drawer clamp 10 is provided with two clamp rails 12 . Clamp rail 12 is illustrated in FIG. 1 as a cylindrical metal rod with a circular cross section. Clamp rail 12 , however, can be made of other materials such as wood or plastic, and can have non-circular cross sections including rectangular, elliptical, and I-shaped cross sections. Connecting members 14 maintain clamp rails 12 in parallel position and attach to the rails at each end. Connecting members 14 are metal rods with circular cross sections in FIG. 1 , but other materials and cross sections can also be used.
[0047] Connecting brackets 22 are used in the preferred embodiment to connect the ends of connecting members 14 to the ends of clamp rails 12 . Connecting members 22 help maintain a perpendicular relationship between connecting members 14 and clamp rails 12 , thereby ensuring that clamp rails 12 remain parallel.
[0048] A sliding clamp 16 is connected to each clamp rail 12 . Bracing member 18 is connected to both sliding clamps 16 , thereby coordinating the movement of the clamps along clamp rails 12 . Bracing member 18 also functions as a clamping surface used to supply force to objects being fastened together as later illustrated and described. In the preferred embodiment face plate 20 is attached to connecting member 14 in a direction parallel to and facing bracing member 18 . Face plate 20 also functions as a clamping surface.
[0049] FIG. 2 illustrates how the present invention is used to clamp a drawer during fabrication. Drawer clamp 10 operates to supply clamping force to drawer frame 26 as the pieces are fastened together. Drawer 24 is assembled between bracing member 18 and face plate 20 . Drawers are commonly assembled by adjoining four frame members together forming drawer frame 26 and drawer base 28 .
[0050] Many methods can be used to fasten the members of the frame together. One common method of fabrication involves the use of wood glue or a combination of wood glue and dowels or discs as a fastening means. If wood glue is used, the user can dispense wood glue along joints 44 in drawer frame 26 . The glued drawer can be placed between face plate 20 and bracing member 18 . Bracing member 18 can be slid down clamp rail 12 by sliding the clamps until contact is made with drawer frame 26 . Since wood glue creates its tightest bond when it dries under compression, sliding clamps 16 can then be used to tighten bracing member 18 and front plate 20 around the assembly so as to supply compressive force to the frame members. Force is supplied to the drawer by the clamp using a levered-clamping means which is described later. The drawer is then retained in the clamp until the glue dries.
[0051] Other methods of fabrication involve the use of other means of attachment such as screws, nails, and staples. The drawer clamp can be used in these methods to provide a means of alignment of the drawer frame as the frame members are attached together. The user can assemble the frame between bracing member 18 and face plate 20 , and then bring bracing member 18 into contact with drawer frame 26 . The frame members can then be adjusted into alignment and sliding clamps 16 can be used to provide clamping force to drawer frame 26 as the frame is nailed, screwed, or stapled together.
[0052] A detailed view of a preferred embodiment of the sliding clamp mechanism is shown in FIG. 3 . Bracing bracket 36 is attached to bracing member 18 . Bracing bracket 36 has orifice 40 which is sized to receive non-threaded shank 38 of sliding clamp 16 . Threaded shank 32 is fed through threaded orifice 46 of clamp bracket 34 . Clamp bracket 34 has rail orifice 48 through which clamp rail 12 passes, thereby facilitating slidable engagement of clamp bracket 34 with clamp rail 12 . FIG. 4 shows a top view of clamp bracket 34 with rail orifice 48 and threaded orifice 46 for clearer illustration.
[0053] With reference to FIG. 3 , the clamp is tightened by turning handle 30 . Those skilled in the art will understand that rotation of handle 30 of sliding clamp 16 will increase the distance between clamp bracket 34 and bracing member 18 . Clamp bracket 34 operates as a lever when handle 30 is turned and creates a pinch-point between rail orifice 48 and clamp rail 12 as bracing member 18 is compressed against the drawer. This lever action prevents the translational movement of clamp bracket 34 vis-à-vis clamp rail 12 .
[0054] Other sliding clamp mechanisms can be used to accomplish a similar levered-clamping action. FIG. 5 shows a modified sliding clamp. Sliding clamp 16 features spring toggle 60 and ratcheting lever 58 for improved gripping of clamp rail 12 by sliding clamp 16 . The user operates the clamp by squeezing spring toggle 60 towards handle 56 and sliding sliding clamp 16 down clamp rail 12 until bracing member 18 comes in contact with the object to be clamped. Spring toggle 60 has an orifice (not shown) through which clamp rail 12 passes such that sliding clamp 16 can slide freely along clamp rail 12 when spring toggle 60 is depressed but will not slide when spring toggle 60 is released because of friction between spring toggle 60 and clamp rail 12 . The user can then squeeze ratcheting lever 58 towards handle 56 , thereby tightening the clamp around the object to be clamped.
[0055] FIG. 6 shows the sliding clamp of FIG. 3 featuring a spring toggle. Spring toggle 60 can be added to any sliding clamp to improve the grip of clamp bracket 34 with respect to clamp rail 12 . The spring toggle of the embodiment shown in FIG. 5 operates the same as spring toggle 60 in FIG. 4 .
[0056] FIG. 7 shows the sliding clamp of FIG. 3 featuring a screw tightener. Like spring toggle 60 , screw tightener 62 can be added to any sliding clamp to improve the grip of clamp bracket 34 with respect to clamp rail 12 . When screw tightener 62 is rotated, screw tightener 62 bears against clamp rail 12 , thereby increasing the frictional force between clamp rail 12 and clamp bracket 34 and screw tightener 62 and preventing the translational movement of clamp bracket 34 vis-à-vis clamp rail 12 .
[0057] In addition, clamp rails 12 can be altered to improve the levered-clamping action. Alternate embodiments of the clamp rail are shown in FIGS. 8A and 8B . FIG. 8A shows clamp rail 12 enhanced with notches 50 . This treatment to the surface of clamp rail 12 can improve its “gripability” by providing a surface that is closer to perpendicular with respect to rail orifice 48 when the levered-clamping action causes rail orifice 48 to mate with clamp rail 12 . A similar effect can be created by enhancing the surface of clamp rail 12 with ridges 52 as illustrated in FIG. 8B .
[0058] An alternate embodiment of the invention is shown in FIG. 9 . The alternate embodiment features only one sliding clamp 16 instead of two. In the place of the second sliding clamp, elongated bracing member 18 with orifice 42 is provided to engage clamp rail 12 . Similarly, as illustrated in FIG. 10 , gripping bracket 54 with orifice 42 can also be used in place of the second sliding clamp to engage clamp rail 12 . In both of these embodiments clamping force is provided by turning single sliding clamp 16 .
[0059] Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. As an example, drawer clamp 10 is not solely for the fabrication of drawers and wordworking but can instead be used for any application where such a clamp is needed. | A new clamp for woodworking. The clamp features two parallel clamp rails joined at each end by connecting members. The movement of sliding clamps along the clamp rails is coordinated by a bracing member which connects the sliding clamps together and provides a clamping surface. | 1 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of printing and in particular, to methods for optimizing memory and processing requirements during rasterization and rendering of high resolution compressed images.
[0003] 2. Description of Related Art
[0004] High resolution digital images are a common component of electronically stored documents. These images may often be defined by high colorimetric and spatial resolution. High resolution images can occupy large amounts of memory and are therefore often stored in compressed formats, such as Joint Photographic Experts Group (“JPEG”) or Portable Network Graphics (“PNG”). Even lower resolution images can occupy significant amounts of memory. In uncompressed form, the images may be described by a bitmap.
[0005] Electronic documents that include compressed images may often require decompression prior to both rasterization and integration into the display lists. The decompression process, however, may consume significant computing resources and accordingly degrade performance. Moreover, decompressed high-resolution images may often exceed the storage capacity typically allocated for a display lists. In these cases, a swap file on secondary storage or other storage media may be used to provide additional storage capacity. However, time delays in accessing swap files in secondary storage may introduce additional delays and consume other resources potentially available for rasterization thereby reducing printer performance. Thus, there is a need for methods and systems to optimize the rasterization and rendering of documents with image content for printing.
SUMMARY
[0006] In accordance with the present invention, systems and methods for rendering print data are presented. In some embodiments, a method for rendering print data, wherein the print data comprises at least one compressed image object, the method comprising generating a display list by parsing the print data, wherein the at least one compressed image object is identified in the display list by a reference to the at least one compressed image object; and rasterizing the display list, wherein rasterization further comprises using the reference to the at least one compressed image object to retrieve the at least one compressed image object; decoding the retrieved compressed image object; and creating a bitmap using the decoded image object.
[0007] Embodiments of the present invention also relate to instructions created, stored, accessed, or modified by processors using computer-readable media and/or computer-readable memory.
[0008] These and other embodiments are further explained below with respect to the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows a block diagram illustrating components in a system for printing documents.
[0010] FIG. 2 shows a high level block diagram of an exemplary printer.
[0011] FIG. 3 shows an exemplary high-level data flow between modules in a system for rendering print data.
[0012] FIG. 4 shows an exemplary lower level data flow between modules in an exemplary raster information processor module for rendering print data.
[0013] FIG. 5 shows a flowchart illustrating steps in an exemplary method for rendering print data.
DETAILED DESCRIPTION
[0014] Reference will now be made in detail to one or more exemplary embodiments of the present invention as illustrated in the accompanying drawings to refer to the same or like parts.
[0015] FIG. 1 shows a block diagram illustrating components in a system for printing documents according to some embodiments of the present invention. A computer software application consistent with the present invention may be deployed on a network of computers, as shown in FIG. 1 , that are connected through communication links that allow information to be exchanged using conventional communication protocols and/or data port interfaces.
[0016] As shown in FIG. 1 , exemplary system 100 includes computers including computing device 110 and server 130 . Further, computing device 110 and server 130 may communicate over connection 120 , which may pass through network 140 , which in one case could be the Internet. Computing device 110 may be a computer workstation, desktop computer, laptop computer, or any other computing device capable of being used in a networked environment. Server 130 may be a platform capable of connecting to computing device 110 and other devices (not shown). Computing device 110 and server 130 may be capable of executing software (not shown) that allows the printing of documents using printers 170 .
[0017] Exemplary printer 170 includes devices that produce physical documents from electronic data including, but not limited to, laser printers, ink-jet printers, LED printers, plotters, facsimile machines, and digital copiers. In some embodiments, printer 170 may also be capable of directly printing documents received from computing device 110 or server 130 over connection 120 . In some embodiments, such an arrangement may allow for the direct printing of documents, with (or without) additional processing by computing device 110 or server 130 . In some embodiments, documents may contain one or more of text, graphics, and images. Image data may be compressed when stored in electronic form. Accordingly, decompression may be performed on compressed image data prior to printing. In some embodiments, printer 170 may receive PDL or PPML descriptions of documents for printing. A PDL description is often translated to a series of lower-level printer-specific commands when the document is being printed. The process of translation from a PDL description of a document to a lower-level description that may be used to place marks on a print medium is termed rasterization.
[0018] Note that document print processing can be distributed. Thus, computing device 110 , server 130 , and/or the printer may perform portions of document print processing such as half-toning, color matching, and/or other manipulation processes before a document is physically printed by printer 170 .
[0019] Computing device 110 also contains removable media drive 150 . Removable media drive 150 may include, for example, 3.5 inch floppy drives, CD-ROM drives, DVD ROM drives, CD±RW or DVD±RW drives, USB flash drives, and/or any other removable media drives consistent with embodiments of the present invention. In some embodiments, portions of the software application may reside on removable media and be read and executed by computing device 110 using removable media drive 150 .
[0020] Connection 120 couples computing device 110 , server 130 , and printer 170 and may be implemented as a wired or wireless connection using conventional communication protocols and/or data port interfaces. In general, connections 120 can be any communication channel that allows transmission of data between the devices. In one embodiment, for example, the devices may be provided with conventional data ports, such as parallel ports, serial ports, Ethernet, USB, SCSI, FIREWIRE, and/or coaxial cable ports for transmission of data through the appropriate connection. In some embodiments, connection 120 may be a Digital Subscriber Line (DSL), an Asymmetric Digital Subscriber Line (ADSL), or a cable connection. The communication links could be wireless links or wired links or any combination consistent with embodiments of the present invention that allows communication between the various devices.
[0021] Network 140 could include a Local Area Network (LAN), a Wide Area Network (WAN), or the Internet. In some embodiments, information sent over network 140 may be encrypted to ensure the security of the data being transmitted. Printer 170 may be connected to network 140 through connection 120 . In some embodiments, printer 170 may also be connected directly to computing device 110 and/or server 130 . System 100 may also include other peripheral devices (not shown), according to some embodiments of the present invention. A computer software application consistent with the present invention may be deployed on any of the exemplary computers, as shown in FIG. 1 . For example, computing device 110 could execute software that may be downloaded directly from server 130 . Portions of the application may also be executed by printer 170 in accordance with some embodiments of the present invention.
[0022] FIG. 2 shows a high-level block diagram 200 of exemplary printer 170 . In some embodiments, printer 170 may contain bus 174 that couples CPU 176 , firmware 171 , memory 172 , input-output ports 175 , print engine 177 , and secondary storage device 173 . Exemplary secondary storage 173 may be an internal or external hard disk, memory stick, or any other memory storage device capable of being used by system 200 . Printer 170 may also contain other Application Specific Integrated Circuits (ASICs), and/or Field Programmable Gate Arrays (FPGAs) 178 that are capable of executing portions of an application to print documents according to some embodiments of the present invention. In some embodiments, printer 170 may also be able to access secondary storage or other memory in computing device 110 using I/O ports 175 and connection 120 . In some embodiments, printer 170 may also be capable of executing software including a printer operating system and other appropriate application software. In some embodiments, printer 170 may allow paper sizes, output trays, color selections, and print resolution, among other options, to be user-configurable.
[0023] In some embodiments, CPU 176 may be a general-purpose processor, a special purpose processor, or an embedded processor. CPU 176 can exchange data including control information and instructions with memory 172 and/or firmware 171 . Memory 172 may be any type of Dynamic Random Access Memory (“DRAM”) such as but not limited to SDRAM, or RDRAM. Firmware 171 may hold instructions and data including but not limited to a boot-up sequence, pre-defined routines, and other code. In some embodiments, code and data in firmware 171 may be copied to memory 172 prior to being acted upon by CPU 176 . Routines in firmware 171 may include code to translate page descriptions received from computing device 110 to display lists and image bands. In some embodiments, firmware 171 may include rasterization routines to convert display commands in a display lists to an appropriate rasterized bit map and store the bit map in memory 172 . Firmware 171 may also include compression and decompression routines and memory management routines. In some embodiments, data and instructions in firmware 171 may be upgradeable.
[0024] In some embodiments, CPU 176 may act upon instructions and data and provide control and data to ASICs/FPGAs 178 and print engine 177 to generate printed documents. In some embodiments, ASICs/FPGAs 178 may also provide control and data to print engine 177 . FPGAs/ASICs 178 may also implement one or more of translation, compression, decompression, and rasterization algorithms. In some embodiments, computing device 110 can transform document data into a first printable data. Then, the first printable data can be sent to printer 170 for transformation into intermediate printable data. Printer 170 may transform intermediate printable data into a final form of printable data and print according to this final form.
[0025] In some embodiments, rasterization may be performed using ASIC/FPGA 178 , CPU 176 , or a combination thereof. In other embodiments, rasterization may also be performed using software, firmware, hardware, or combination thereof. For example, ASIC/FPGA 178 , CPU 176 , or a combination thereof may be used to convert PDL formatted data into intermediate data, which may take the form of a display list, and may include a list of objects and low-level drawing commands associated with the objects. Once the display list is complete, ASIC/FPGA 178 , CPU 176 , or a combination thereof can rasterize the objects, transform the raw bit map, and provide a bitmap to a frame buffer or print engine to place marks on printable media. In some embodiments, the first printable data may correspond to a PDL or PPML description of a document.
[0026] FIG. 3 shows an exemplary high-level data flow 380 between modules in a system for rendering print data. As shown in FIG. 3 , the system comprises, inter alia, RIP module 300 , secondary storage 173 , and frame buffer 370 . RIP module 300 may comprise parser 330 , decoder 350 , and rasterizer 360 . In some embodiments, parser 330 , decoder 350 , and rasterizer 360 communicate with each other and may also create, modify, and perform other operations on display lists 340 .
[0027] As shown in FIG. 3 , parser 330 can receive print job 310 from computing device 110 and may use PDL language objects present in print job 310 to generate display lists 340 . In other embodiments, display lists 340 may hold one or more of text, graphics, command, image header, and image data objects. These display commands may include data comprising characters or text, line drawings or vectors, and images or raster data. In some embodiments, objects in display lists 340 may correspond to similar objects in a user document. In some embodiments, display lists 340 may be stored in memory 172 or secondary storage 173 . In some embodiments, the display lists may reside in one or more of printer 170 , computing device 110 , and server 130 . Memory to store display lists may be a dedicated memory or form part of general purpose memory, or some combination thereof according to disclosed embodiments. Display lists 340 may be a second or intermediate step in the processing of data prior to actual printing and may be parsed before conversion into a subsequent form. In some embodiments the subsequent form may be a final representation.
[0028] In some embodiments, RIP module 300 may be implemented as a software application, or in firmware 171 using CPU 176 ; or using ASIC/FPGA 178 , or by some combination thereof. RIP module 300 can receive and operate on data in print job 310 to facilitate the generation of frame buffer 370 . In some embodiments, print job 310 may comprise a sequence of drawing commands and language objects. The sequence may include drawing commands associated with text objects, graphics objects, and/or image objects. In some embodiments, the images corresponding to image objects in print job 310 may comprise high-resolution images. High resolution images may be defined by high calorimetric and spatial resolution.
[0029] In some embodiments, the images corresponding to image objects in print job 310 may be compressed using common compression algorithms, including but not limited to JPEG, GIF, TIFF and/or PNG. In some embodiments, the images corresponding to image objects associated with print job 310 may be stored in secondary storage 173 . In other embodiments, images corresponding to image objects associated with print job 310 may stored on other computer readable storage media coupled to computing device 110 or printer 170 (not shown) either alone or in combination with secondary storage 173 .
[0030] In one embodiment, a reference pertaining to the image stored in secondary storage 173 may be used in display list 340 to identify and locate the image. In some embodiments, the reference may include an image header and/or other identifying and location information. In some embodiments, the reference may point to the location of the image object in memory, or in secondary storage. For example, the reference may include a pointer to a read function providing access to the image. The pointer may provide address and other information associated with the image object.
[0031] in some embodiments, processing print job 310 by parser 330 may comprise placing drawing commands associated with text and graphics directly into display list 340 based on a PDL definition associated with print job 310 . In cases where print job 310 contains images, parser 330 can place an image header or some other descriptive reference corresponding to the image object in display list 340 . In some embodiments, images in the print job may continue to remain in compressed form in memory or in secondary storage.
[0032] In some embodiments, decoder 350 can use image header or other image identification information in display list 340 to decompress retrieved compressed images. For example, decoder 350 can request the retrieval of compressed images from secondary storage 173 using information present in the reference to image objects in display list 340 . In some embodiments, decoder 350 can then decompresses the compressed image.
[0033] In some embodiments, the reconstruction of the uncompressed image may proceed scan line by scan line in order from top to bottom. A scan line may be described as a 1×N array of pixels, where N may represent a first integer value. In some situations, a scan line may additionally be described as 1 to M planes deep. Here, M may represent a second integer value. For example, when image data consists of information in M multiple color planes, the scan line may include 1 line of data comprising of N pixels for each of the M color planes. Decoder 350 may receive a pointer to a read function to access an image from secondary storage 173 . In some embodiments, the read function may be system specific. Decoder 350 may also output scan lines for reconstructing the decompressed image. In some embodiments, decoder 350 may be implemented in one of hardware, software, or some combination thereof. For example, decoder 350 may be implemented in firmware 171 , CPU 176 , ASIC/FPGA 178 , or some combination thereof.
[0034] In some embodiments, rasterizer 360 can read data and drawing commands from display lists 340 and decompressed scan lines from decoder 350 . and store its output in frame buffer 370 . In some embodiments, frame buffer 370 may be part of memory 172 . In some embodiments, data in frame buffer 370 may be organized as discrete horizontal bands to optimize processing. Frame buffer 370 may hold a rectangular bitmap specifying the marks to be made on a printed page for print job 310 . Print engine 177 , may process the rasterized data in frame buffer 370 , and form a printable image of the page on a print medium, such as paper. In some embodiments, routines for rasterizer 360 may be provided in firmware 171 or may be implemented using ASICs/FPGAs 178 .
[0035] FIG. 3 shows some functional blocks in an exemplary system for rendering print data, the modules and/or functional blocks shown can be implemented variously using hardware, software, or some combination of hardware and software. For example, CPU 176 could copy parser 330 from firmware 171 to memory 172 and execute parsing operations on the data in print job 310 . Decoding and decompression operations may be implemented using ASIC and/or FPGAs 178 and operate under the control of an operating system for printer 170 running on CPU 176 .
[0036] FIG. 4 shows a lower level data flow 480 between modules in exemplary raster information processor module 300 for rendering print data. In some embodiments, rasterizer 360 may include, among other things, master rasterizer 400 and slave rasterizers 410 , including one or more slave rasterizers 410 - 1 - 410 - n, where n is the integral number of slave rasterizers. Master rasterizer 400 may receive drawing commands from display lists 340 to arbitrate and control execution of drawing command sequences among some combination of slave rasterizers 410 - 1 , 410 - 2 , through 410 - n. In some embodiments, master rasterizer 400 may also be coupled to decoder 350 to direct decompressed scan lines from decoder 350 to a particular slave rasterizer for rendering.
[0037] In some embodiments, slave rasterizers 410 - 1 , 410 - 2 , through 410 - n may execute drawing commands associated with a particular region of frame buffer 370 . As shown in FIG. 4 , memory frame buffer 370 may be segmented into a plurality of distinct contiguous bands 440 to receive the output of rasterizer 360 . For example, frame buffer band 1 440 - 1 may be coupled to receive the output of slave rasterizer 410 - 1 . Similarly, in other embodiments, frame buffer band 2 440 - 2 through frame buffer band n 440 -n may also be coupled to receive the output of slave rasterizer 2 410 - 2 through slave rasterizer n 410 - n, respectively. In some embodiments, slave rasterizer 1 410 - 1 is coupled to receive a scan line output from decoder 350 . The output of decoder 350 may point to a scan line buffer in the process space of slave rasterizer 1 410 - 1 based on master rasterizer 400 . Similarly, in other embodiments, the output of decoder 350 may point to scan line buffers in the process space of slave rasterizer 2 410 - 2 through slave rasterizer n 410 - n.
[0038] In some embodiments, decoder 350 and rasterizer 360 may process compressed images and display lists 340 commands in parallel. In some embodiments, decoder 350 can decompress an image sequentially, reconstructing each image referenced by an image header in display lists 340 scan line by scan line in order from top to bottom. Decoder 350 can provide the decompressed scan lines to rasterizer 360 for processing in the same order as the original image was compressed. For example, in one embodiment, one or more slave rasterizers 4101 can rasterize the decompressed scan lines in the same logical order that was used to compress the original image. In other embodiments, parallel processing may be performed by running decoder 350 on one core of a CPU 176 with multiple cores and running rasterizers 400 and 410 on another core of CPU 176 .
[0039] FIG. 5 shows a flowchart 580 illustrating the steps in an exemplary method for rendering print data. It will be readily appreciated by one having ordinary skill in the art that the illustrated procedure can be altered to combine, delete and/or move steps, or further include additional steps to perform the desired operations. In step 500 , print job 310 is received from computing device 110 . In some embodiments, data in print job 310 may be received by parser 330 . Moreover, print job 310 may comprise a sequence of language objects and drawing commands. The sequence of drawing commands, which may include drawing commands associated with text, graphics, or images, may be passed to parser 330 . In some embodiments, the images contained in print job 310 may be compressed.
[0040] In step 510 , display list 340 is generated based on print job 310 . In some embodiments, parser 330 may generate display list 340 . For example, parser 330 may provide drawing commands associated with text and graphics directly into display lists 340 based on a PDL definition associated with print job 310 . In some embodiments, print job 310 may also include a pointer or image header corresponding to a compressed image stored on secondary storage 173 . In these cases, parser 330 may store the image header in the display lists 340 instead of the fully decompressed images themselves.
[0041] In step 520 , a compressed image is retrieved using an image header and/or other image identifying or location information. In some embodiments, the image header may include a pointer to a read function providing access to secondary storage 173 . In step 530 , a compressed image identified and located by the image header in display lists 340 can be decoded. In some embodiments, decoder 350 may generate an uncompressed image as sequential decompressed scan lines, ordered from the top of the image to the bottom of the image. In some embodiments, steps 530 and 540 may be performed in parallel.
[0042] In step 540 , objects in display lists 340 , including image objects identified by references in display lists 340 , may be rasterized. For example, rasterization of display lists 340 and each associated compressed image may be performed by rasterizer 360 . For example, rasterizer 360 may generate a frame buffer by reading drawing commands from display lists 340 and rendering decompressed scan lines of each image associated with each image header.
[0043] In some embodiments, the rasterization process may be divided among a plurality of slave rasterizers, each slave rasterizer generating a particular region of the frame buffer. For example, drawing commands received by rasterizer 360 may be processed by slave rasterizers 410 - 1 though 410 - n. Accordingly, drawing commands and decompressed scan lines associated with a particular band of frame buffer 370 may be assigned for processing to one of a plurality of slave rasterizers 410 by master rasterizer 400 . For example, slave rasterizer 1 410 - 1 , slave rasterizer 2 410 - 2 , through slave rasterizer n 410 - n may operate on frame buffer band 1 440 - 1 , frame buffer band 2 440 - 2 , through frame buffer band n 440 - n, respectively. In some embodiments, master rasterizer 400 may arbitrate the execution of drawing commands in display lists 340 across multiple slave rasterizers coupled to a particular region of the frame buffer. In addition, master rasterizer 400 may signal to decoder 350 to direct its output to a scan line buffer in the process space associated with a particular slave rasterizer.
[0044] In step 550 , rasterized scan lines may be transformed to adjust a scan line prior to output to frame buffer 370 . For example, slave rasterizer 1 410 - 1 , slave rasterizer 2 410 - 2 , through slave rasterizer n 410 - n may each transform their rasterized outputs prior to transport to frame buffer 370 . In some embodiments, geometrical transformation may comprise, shifting, scaling, or other operations applied to pixels of a scan line. For example, slave rasterizer 410 - 1 may generate a scan line comprised of 1×N pixels. In some embodiments, slave rasterizer 410 - 1 may shift the scan line, scale the scan line, or perform a combination thereof to properly position the scan line for placement into frame buffer 370 . Shifting may comprise an operation applied to all pixels of the scan line to place the drawing object in the correct location within frame buffer 270 . In scaling an operation is applied to all pixels to resize an object and/or change the aspect ratio of the object.
[0045] Other embodiments of the present invention will be apparent to those skilled in the art from consideration of the specification and practice of one or more embodiments of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. | Systems and methods consistent with some embodiments presented provide methods for rendering print data. In some embodiments of methods for rendering print data comprising at least one compressed image object may include generating a display list by parsing the print data. The compressed image object may be identified in the display list by a reference to the at least one compressed image object. In some embodiments, the display list may be rasterized and converted to a bitmap. In some embodiments, the reference to the at least one compressed image object may be used to retrieve the at least one compressed image object. The retrieved compressed image object may be decoded and rasterized to generate a bitmap of the decoded image. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ultrasonic wave motor, and more particularly to an ultrasonic wave motor utilizing a rectangular wave signal for producing vibrational energy as a driving source.
2. Description of the Related Art
The principle of operation of a generally known standing wave type ultrasonic wave motor is such that a movable member is contacted under a predetermined pressure by an ultrasonic wave vibrator adapted to be excited to generate a substantially elliptic vibration, and the movable member is driven by a frictional force between the same, with each material point of the ultrasonic wave vibrator generating a substantially elliptic vibration. Such a standing wave type ultrasonic wave motor can realize high efficiency and large output since a vibration of high efficiency can be easily realized.
It is known that a stacked piezoelectric element is used as an excitation source in a floating direction of the movable member in the ultrasonic wave motor. In this type of ultrasonic wave motor, an excitation signal having a frequency different from a natural vibration frequency of the movable member is applied to the stacked piezoelectric element to drive the movable member under a non-resonant condition. Therefore, it is superior in controllability to another type ultrasonic wave motor utilizing a resonant phenomenon of vibrations in two directions.
However, as a sine wave signal is used as the excitation signal to be applied to the stacked piezoelectric element, a vibration speed of the ultrasonic wave vibrator differs from a moving speed of the movable member during a large proportion of a contact time between the ultrasonic wave vibrator and the movable member. Accordingly, a shearing strain is generated in the ultrasonic wave vibrator, and as the shearing force is larger than the frictional force, slippage is generated between the frictional surfaces to cause a loss of energy.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to overcome the above problems and to provide an ultrasonic wave motor which can greatly reduce the slippage between the frictional surfaces of the ultrasonic wave vibrator and the movable member to thereby realize high responsiveness and high efficiency.
The above and further objects and novel features of the invention will be achieved by an ultrasonic wave motor comprising (a) an elastic member; (b) a movable member; (c) a first electrical/mechanical energy converting member for applying to the elastic member a vibration in a moving direction of the movable member; (d) a second electrical/mechanical energy converting member interposed between the elastic member and the movable member for applying to the movable member a vibration in a floating direction of the movable member; and (e) a driving source comprising means for applying a rectangular wave excitation signal to the second electrical/mechanical energy converting member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail with reference to the following drawings, wherein:
FIG. 1 is a perspective view of the ultrasonic wave motor according to a preferred embodiment of the present invention;
FIG. 2A is a perspective view of an annular piezoelectric element employed in the ultrasonic wave motor;
FIG. 2B is a schematic illustration of a shearing vibrational condition of the annular piezoelectric elements when sine waves of reverse phases are applied thereto;
FIG. 3 is a graph showing an amplitude-time characteristic of the stacked piezoelectric elements and the movable member when a sine wave is applied to the stacked piezoelectric elements;
FIGS. 4A, 4B and 4C are graphs showing the relationship among an amplitude Ux (FIG. 4A) of the elastic member in its circumferential direction (X-direction), an amplitude Uy (FIG. 4C) of the stacked piezoelectric elements in their stacked direction (Y-direction), a speed Vx (FIG. 4B) of the stacked piezoelectric elements in their circumferential direction (X-direction) and a rotating speed Vr (FIG. 4B) of the movable member; and
FIGS. 5A to 5E are illustrations of the behavior of the stacked piezoelectric elements and the movable member on the frictional surfaces thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A detailed description of one preferred embodiment of an ultrasonic wave motor embodying the present invention will now be given referring to the accompanying drawings. As shown in FIG. 1, an ultrasonic wave motor 11 includes a pair of annular piezoelectric elements 21a and 21b interposed between a pair of elastic members 22 and 23. As shown in FIG. 2A, each of the annular piezoelectric elements 21a and 21b is formed by annularly bonding eight divided pieces. Further, as shown in FIG. 2B, the annular piezoelectric elements 21a and 21b are arranged in such a manner that positive poles are opposed to each other and negative poles are positioned on the opposite sides. The annular piezoelectric elements 21a and 21b are electrically connected to a common sine wave AC power source (first power source) 41. Accordingly, the annular piezoelectric elements 21a and 21b are adapted to be excited to generate shearing vibrations having reverse phases. The elastic members 22 and 23 are formed of metal such as aluminum and brass or ceramic.
Three stacked piezoelectric elements 26 (26a, 26b and 26c) are disposed on an upper surface of the elastic member 22. The stacked piezoelectric elements 26a to 26c are electrically connected in parallel to a common second power source 42. The second power source 42 includes a sine wave generating power source 42a and a rectangular wave generating power source 42b, which are selectively connected to the stacked piezoelectric elements 26a to 26c. The first power source 41 and the second power source 42 are selectively actuated by a control circuit 43 during time periods described herein. A disk-shaped movable member 31 is disposed on the stacked piezoelectric elements 26a to 26c, and it is mechanically fixed with the elastic members 22 and 23 and the annular piezoelectric elements 21a and 21b by means of a bolt 24 and a nut 25.
The operation of the ultrasonic wave motor 11 mentioned above will now be described with reference to FIGS. 3 to 5.
Referring to FIG. 3, when a sine wave is applied to the stacked piezoelectric elements 26, the stacked piezoelectric elements 26 are expanded and contracted in a stacked direction thereof to displace the movable member 31 in its floating direction. An amplitude of expansion and contraction of the stacked piezoelectric elements 26 depends proportionally on a magnitude of a sine wave AC voltage to be applied to the second power source 42. When the stacked piezoelectric elements 26 are contracted under the condition where they contact the movable member 31, the movable member 31 separates from the top surfaces of the stacked piezoelectric elements 26. Thereafter, while the movable member 31 is being lowered by gravity, the stacked piezoelectric elements 26 are expanded again to come into contact with the movable member 31 and thereby lift the movable member 31. In FIG. 3, an area shown by a dashed line denotes a contact condition of the stacked piezoelectric elements 26 with the movable member 31. Under the contact condition, a torque is transmitted from the elastic member 22 through the stacked piezoelectric elements 26 to the movable member 31.
First, a sine wave AC voltage having a resonance frequency f corresponding to a natural oscillation frequency of the elastic members 22 and 23 is applied from the first power source 41 to the piezoelectric elements 21a and 21b, so as to vibrate the piezoelectric elements 21a and 21b, so that a resonance vibration of a torsional vibration mode is generated in the elastic members 22 and 23. Then, the sine wave generating power source 42a is selected by the control circuit 43 to be connected to the stacked piezoelectric elements 26, so as to apply a sine wave AC voltage having a frequency f to the stacked piezoelectric elements 26 and thereby vibrate the stacked piezoelectric elements 26. At this time, a substantially elliptic vibration of an arbitrary shape can be generated in the stacked piezoelectric elements 26 by adjusting an amplitude and a phase of the voltage to be applied to the piezoelectric elements 21a and 21b.
FIGS. 4A-4C show the relationship between a displacement width (amplitude) Ux of the elastic member 22 in the X-direction and a displacement speed Vx of the stacked piezoelectric elements 26 in the X-direction to be given by the vibration of the elastic member 22, and also show an application timing chart of a rectangular wave to be applied to the stacked piezoelectric elements 26. Uy denotes a displacement width (amplitude) of the stacked piezoelectric elements 26 in the Y-direction. Vr denotes a rotating speed of the movable member 31. It is assumed that the movable member 31 is rotated under a substantially steady rotational condition at the constant speed of Vr=VR (i.e., steady state). In this case, when the displacement width Ux of the elastic member 22 tends to increase, and the displacement speed Vx of the stacked piezoelectric elements 26 is substantially equal to the rotating speed Vr (≈VR) of the movable member 31, the sine wave AC voltage to the stacked piezoelectric elements 26 is discontinued, and a rectangular wave excitation signal is input to the stacked piezoelectric elements 26 (Point A in FIG. 4B). Accordingly, the stacked piezoelectric elements 26 are expanded in the floating direction of the movable member 31. Further, as the displacement width Ux of the elastic member 22 tends to increase, a shearing strain is generated in the stacked piezoelectric elements 26 to thereby accelerate the movable member 31 (Point B in FIG. 4B). As the acceleration of the movable member 31 proceeds, the displacement speed Vx of the stacked piezoelectric elements 26 is reduced (Points C and D in FIG. 4B). Thereafter, when the rectangular wave signal is cut off, the strain is eliminated (Point E in FIG. 4B). As a result, the accelerated condition of the movable member 31 is changed into a substantially constant speed condition. The same motion as above is repeated at the timing when the rectangular wave excitation signal is input again. FIGS. 5A to 5E show various conditions of the elastic member 22, the stacked piezoelectric elements 26 and the movable member 31 at the points A to E shown in FIG. 4B, respectively. A duty ratio t1/t2 is set so that the rectangular wave signal is input in the period between the point A and the point E.
Such a dynamic control makes it possible to transmit all the strain energy stored in the stacked piezoelectric elements 26 to the movable member 31, thereby greatly reducing a loss at a sliding portion between the piezoelectric elements 26 and the movable member 31.
As described above, the ultrasonic wave motor 11 is provided with the stacked piezoelectric elements 26 as an excitation source, and employs a substantially rectangular wave as an excitation signal for floating the movable member 31. Therefore, the sliding of the frictional surfaces between the piezoelectric elements 26 and the movable member 31 can be greatly reduced to thereby improve responsiveness and efficiency of the ultrasonic wave motor.
Further, a duty ratio of the standing wave in the floating direction is controlled by the control circuit 43. When the displacement speed of the stacked piezoelectric elements 26 becomes substantially equal to the rotating speed of the movable member 31, the former comes into contact with the latter, while when the shearing strain near the contact surface between the former and the latter is substantially eliminated, the former separates from the latter. Therefore, the strain energy stored in the stacked piezoelectric elements 26 is entirely transmitted to the movable member 31, thereby greatly reducing a loss at the sliding portion.
The present 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 appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. For instance, although the above preferred embodiment utilizes a torsional vibration to be generated by the ultrasonic wave vibrator, various other vibrations such as vertical vibration, bending vibration or shearing vibration may be utilized. Further, a higher mode may be utilized.
Although the piezoelectric elements are employed as the excitation source for the elastic members in the above preferred embodiment, any other elements capable of converting electrical energy into mechanical energy, e.g., an electrostrictive element or a magnetostrictive element may be used. Further, the shape of the elastic members and the movable member is not limited to a circular shape, but any other shapes such as a planar, annular, rod-like or rectangular shapes may be employed. | An ultrasonic wave motor includes an elastic member, a movable member, a first electrical/mechanical energy converting member for applying to the elastic member a vibration in a moving direction of the movable member, a second electrical/mechanical energy converting member interposed between the elastic member and the movable member for applying to the movable member a vibration in a floating direction of the movable member, and a driving source for applying a rectangular wave excitation signal to the second electrical/mechanical energy converting member. With this construction, slippage between the movable member and the second electrical/mechanical energy converting member can be eliminated to thereby achieve efficient transmission of energy. | 7 |
FIELD OF THE INVENTION
The present invention relates to a machine for continuous centrifugation of fabrics, particularly for the removal of scouring, dye or other liquors.
DESCRIPTION OF THE PRIOR ART
In many fabric finishing processes, it is necessary to remove therefrom the liquors that they have absorbed. A first stage of this operation is frequently based on centrifugation of the fabric, whereby the moisture contained therein is considerably reduced, moisture levels of 50% being considered as satisfactory.
Nevertheless, the commonly known fabric centrifugation apparatus and devices have several drawbacks. In the first place, they usually operate on a batch basis, i.e., the fabric must be charged in the centrifuge, the operation must be carried out during the desirable period of time and the machine must subsequently be unloaded. This is a slow, laborious job. Furthermore, centrifuges usually twists the fabric, this being usually harmful and also requires a further operation to remove the twists that have occurred.
SUMMARY OF THE INVENTION
In view of this, it is an object of the invention to provide an orbital movement wherewith the above drawbacks do not occur.
The above object is attained by a machine of the type stated hereinbefore, comprising:
(a) a hauling means, formed by a first pair of mutually parallelly disposed end rollers; a first endless band adapted to run continuously around each roller of said pair, having a lower inoperative run and an upper operative run; a second pair of end rollers disposed parallel to each other and also to the rollers of the first pair; and a second endless band adapted to run continuously around each roller of said second pair, having an upper inoperative run and a lower operative run, such that said operative runs of each band are facing one another;
(b) a central block formed by: two equal coaxial suspended pulleys, each having at least three peripheral grooves and an eccentric circular aperture; and connecting means for rigidly connecting both pulleys together;
(c) guide means for said bands, comprising: two compound discs, each housed in one of said eccentric circular apertures and having a generally rectangular window; a bearing between each disc and the corresponding suspended pulley; two U-shaped sections extending between both compound discs, corresponding to opposite sides of said windows;
(d) support means for said central block which, for each suspended pulley, comprise a set of three support pulleys, situated generally regularly around the corresponding suspended pulley, there being at least one transmission belt between each support pulley and the corresponding suspended pulley;
(e) a motor to cause said central block to orbit;
(f) a frame surrounding the machine generally along the length thereof.
A machine of the above described nature allows a one end of a piece of fabric to be inserted in the machine in the space formed between the operative runs of each band and cross therethrough, hauled by said bands, until it exits therefrom in a continuous way. While the piece is moving through the machine, it is centrifuged therein, by the orbiting effect of the central block; said orbiting causes a corresponding cylindrical orbital movement of eccentric apertures and of the compound discs housed therein and therefore of the portion of fabric crossing through the central block and at the same time an orbital movement along a conical path of the fabric portions located between the central block and the inlet and delivery points of the fabric. Said movements, as stated above, provide for effective centrifuging without twisting the fabric piece, which is retained always between the bands.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the foregoing, there is described hereinafter a non-limitative embodiment of the machine, with reference to the accompanying drawing, in which:
FIG. 1 is an elevation view of the machine according to the invention, with part of the outer frame broken away to reveal the central block; further portions of the machine have been omitted to avoid making the drawing excessively long;
FIG. 2 is a cross section view on a larger scale, on the line II--II of FIG. 1;
FIG. 3 is a diagrammatic longitudinal section of the machine on a smaller scale than the previous figure, showing only one half thereof, the omitted half being generally symmetrical to the one shown; the motor is not in section and the drive means of the hauling means have been omitted;
FIG. 4 is a plan view of part of the band;
FIG. 5 is a perspective view of one of the complex discs and of the U-shaped sections, shown in cross section, extending between the two compound discs.
DETAILED DESCRIPTION OF THE INVENTION
The machine for continuous centrifugation of fabrics is particularly appropriate for the removal of scouring, dye and other liquors.
In said machine there should be distinguished a hauling means formed by a roller 2 and a roller 4 located at opposite ends of the machine and mounted on generally parallel shafts 6 and 8. A first endless band 10 extends continuously between said first pair of rollers and partially wraps them, forming a lower inoperative run 12 and an upper operative run 14.
There is a second pair of rollers 16 and 18, the respective shafts of which 20 and 22 are mutually parallel and also parallel to the shafts 6 and 8 of the first pair of rollers. Preferably the rollers 16 and 18 are mounted respectively above rollers 2 and 4 of the first pair of rollers; at least one of the shafts 20, 22 is fixed so as to be adapted to be moved a small distance vertically, there being spring means 23, not shown in detail, urging the corresponding roller 16 and/or 18 in the closest possible engagement with the corresponding roller of the first pair.
A second endless band 24 extends continuously between the second pair of rollers 16, 18 and partly wraps them, determining an inoperative top run 26 and an operative lower run 18, such that the operative runs 14 and 18 of each band are mutually facing and spaced a short distance apart.
Drive means 29 for the said rollers cause them to rotate and this rotation causes movement of the bands 10 and 24; this movement is effected in such a way that the said operative runs 14 and 28 move generally at the same speed. Guide rollers 30 suitably engage the inoperative runs 12 and 26 of the bands.
Said drive means 29 are conventional. One possible solution is the use of a motor, not shown, driving a pinion transmitting the movement thereof synchronously to the rollers 2 and 16 by way of transmission chains 33 shown schematically in FIG. 1.
The shafts 6, 20, 8 and 22 are supported in bench frames 32, it being contemplated that there are means, not shown, provided for the shafts 20 and 22 to allow for a slight vertical movement of the shafts 20 and 22, as mentioned above.
The bands 10 and 24 are formed preferably by two or more narrow longitudinal strips 34 to which there are attached by pins or the like a plurality of cross members 36 which are disposed towards the exterior of the band.
In the center of the machine there is a central block 38 formed generally by two suspended pulleys 40 which are identical and coaxial and which are rigidly connected together by connecting means 42 having a plurality of longitudinal passages 44. Each of the pulleys is provided with at least three peripheral grooves, adapted to house belts to be described hereinafter.
As guide means for the operative runs of the bands, each pulley is provided with a circular aperture eccentrically disposed relative to the axis of the pulley and the respective apertures of each pulley are aligned parallel with the axis of the pulley.
In the aperture 48 of each suspended pulley 40 there is a compound disc 50, formed of two superimposed portions. Between the compound disc 50 and the perimeter of the aperture 48 there is a bearing 52 allowing rotation or relative angular movement between the disc and the pulley. The disc comprises the said two superimposed portions to make it possible to mount the disc and the bearing 52 in the aperture 48. The disc has crossing therethrough four rods 54, holding the said two portions together and also serving to mount springs 56 to be described hereinafter.
Each compound disc 50 is also provided with a generally rectangular window 58 and between both windows there extend two U-shaped sections 60 and each section is engaged in opposite sides of the windows 58, precisely in the sides oriented perpendicularly to the bands 10 and 24.
Said U-shaped sections are connected together by cross ties 61 and the unit is mounted to the inner surface of the compound disc 50 by circular sectors 63 which are attached to the compound disc 50 by means of the said rods 54 through orifices 65.
The operative runs 14 and 28 of the bands 10, 24, cross through the windows 58 and during the run thereof between both windows inside the central block 38, the said bands are guided by the sections 60. To facilitate this guiding action and avoid large frictional forces, the inner surface of the sections is covered by an antifriction material 62, generally a plastics material such as nylon, teflon or the like. Furthermore, it is contemplated that said covering 62 should be provided with two grooves 64, each of which is adapted to receive one end of the cross members 36.
The central block 38 is suspended by way of support means formed, for each suspended pulley, by a set of at least three support pulleys 65 and 66, situated generally regularly around the corresponding suspended pulley 40 and duly attached, directly or indirectly, to the frame 68. The lower pulleys 65 are attached to brackets 69 of the frame. Between each support pulley 66 and the corresponding suspended pulley 40 there is at least one transmission belt 80, running in the peripheral grooves 46 of the pulley 40.
The thus suspended central block 38 is adapted to rotate around the axis thereof and preferably the corresponding motor 82 is arranged coaxially with a pulley 66 of each set of pulleys, whereby these pulleys 66 have the dual support and drive function.
Each of the rods 54 of the compound disc 50, as said above, support one end of a spring 56, the other end of which is attached to the frame 68 in corresponding anchor points 81. During the orbital movement of the of the central block 38, the aperture 48 also obviously orbits and, therefore, the said compound discs 50; nevertheless, the effect of the springs 56 is that during the orbiting movement thereof all the positions of the compound discs 50 are always mutually parallel and therefore the windows 58 and sections 60 always retain the same parallel orientation relative to the bands 10 and 24. This constant orientation of the compound discs 50 causes a relative rotation between them and the corresponding suspended pulley, which rotation is facilitated by the bearing 52.
In turn the frame 68 has a generally arch shaped section and surrounds the machine over a substantial length thereof.
The rollers 2 and 16 rotate as indicated by the arrows 82, i.e. in opposite directions. With the said rotations, there is inserted in the nip 84 between the rollers 2 and 16 the end of a fabric piece (not shown), which is hauled in by the bands 10 and 24 along the whole length of the operative runs 14 and 28 of the bands, until it exits from the opposite end of the machine, i.e. the end corresponding to the rollers 4 and 18.
If the fabric piece were thicker than the spacing between the facing bands in the nip 84, the said spring means are overcome and the roller 16 moves slightly, being separated from its closest possible engagement with the roller 2.
With the fabric filling the whole space between the two bands 10 and 24, the central block is caused to orbit, whereby the portion of the fabric piece comprised between the U-shaped sections 60 follows the same cylindrical orbital movement, while the portions of the fabric comprised between the central block and the ends of the machine, orbit around a cone, all simultaneously with a forward feed of the fabric piece between the runs 14 and 28 of the bands 10 and 24.
The speed of orbital movement is adjustable and may reach up to 2,500 r.p.m. and the forward feed speed is about 20 meters per minute.
The orbital movement causes centrifugation of the fabric piece, so that the moisture level of 100 to 120% at the fabric infeed is reduced to 30 to 50% moisture level at the delivery end.
The system, as stated, is continuous and among other advantages it has the one of not twisting or winding the fabric, whereby the latter is not liable to deterioration during its passage through the machine.
The free lateral space between the bands provides for drainage of the liquors, which also flow through the free space between two consecutive cross members 36; said space is the only one allowing for passage of the liquors during the passage of the piece through the central block 38, since the side space is closed by the sections 60.
The apertures 44 of the connecting means 42 also allow for drainage of the liquors from the central block and the frame 68 prevents the centrifugally ejected liquors from dispersing undesirably; said liquors are collected at the bottom 86 of the frame, from where they may be appropriately channelled away. | A machine for the continuous centrifugation of fabrics, comprising: a hauling means for the fabric formed by two endless bands having respective facing runs and an orbitting central block in which there are situated guide means for the bands, such that the latter follow cylindrical orbital paths during the passage thereof through the central block and conical orbital paths from the central block to the infeed and delivery ends of the machine. The orbital movement of the central block causes effective centrifugation of the fabric hauled by the bands, without causing therein harmful pulls or stresses. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of U.S. patent application Ser. No. 10/330,853 filed Dec. 26, 2002, the disclosure of which is incorporated by reference in its entirety.
ACKNOWLEDGEMENT OF GOVERNMENT SUPPORT
[[0002]] This invention was made in part with Government support under a grant from the National Science Foundation (Cooperative Agreement No. DMR-980677). Accordingly, the Government may have certain rights to this invention.
TECHNICAL FIELD
[0003] This invention relates generally to the depolymerization of polymers, and, more particularly relates to an organocatalytic method for depolymerizing polymers using nucleophilic reagents. The invention is applicable in numerous fields, including industrial chemistry and chemical waste disposal, plastics recycling, and manufacturing processes requiring a simple and convenient method for the degradation of polymers.
BACKGROUND OF THE INVENTION
[0004] Technological advances of all kinds continue to present many complex ecological issues. Consequently, waste management and pollution prevention are two very significant challenges of the 21 st century. The overwhelming quantity of plastic refuse has significantly contributed to the critical shortage of landfill space faced by many communities. For example, poly(ethylene terephthalate) (poly(oxy-1,2-ethanediyl-oxycarbonyl-1,4-diphenylenecarbonyl); “PET”), a widely used engineering thermoplastic for carpeting, clothing, tire cords, soda bottles and other containers, film, automotive applications, electronics, displays, etc. will contribute more than 1 billion pounds of waste to land-fills in 2002 alone. The worldwide production of PET has been growing at an annual rate of 10% per year, and with the increase in use in electronic and automotive applications, this rate is expected to increase significantly to 15% per year. Interestingly, the precursor monomers represent only about 2% of the petrochemical stream. Moreover, the proliferation of the use of organic solvents, halogenated solvents, water, and energy consumption in addressing the need to recycle commodity polymers such as PET and other polyesters has created the need for environmentally responsible and energy efficient recycling processes. See Nadkarni (1999) International Fiber Journal 14(3).
[0005] Significant effort has been invested in researching recycling strategies for PET, and these efforts have produced three commercial options; mechanical, chemical and energy recycling. Energy recycling simply burns the plastic for its calorific content. Mechanical recycling, the most widespread approach, involves grinding the polymer to powder, which is then mixed with “virgin” PET. See Mancini et al. (1999) Materials Research 2(1):33-38. Many chemical companies use this process in order to recycle PET at the rate of approximately 50,000 tons/year per plant. In Europe, all new packaging materials as of 2002 must contain 15% recycled material. However, it has been demonstrated that successive recycling steps cause significant polymer degradation, in turn resulting in a loss of desirable mechanical properties. Recycling using chemical degradation involves a process that depolymerizes a polymer to starting material, or at least to relative short oligomeric components. Clearly, this process is most desirable, but is the most difficult to control since elevated temperature and pressure are required along with a catalyst composed of a strong base, or an organometallic complex such as an organic titanate. See Sako et al. (1997) Proc. of the 4 th Int'l Symposium on Supercritical Fluids , pp. 107-110. The use of such a catalyst results in significant quantities of undesirable byproducts, and materials processed by these methods are thus generally unsuitable for use in medical materials or food packaging, limiting their utility. Moreover, the energy required to effect depolymerization essentially eliminates sustainability arguments.
[0006] Accordingly, there is a need in the art for an improved depolymerization method. Ideally, such a method would not involve extreme reaction conditions, use of metallic catalysts, or a process that results in significant quantities of potentially problematic by-products.
SUMMARY OF THE INVENTION
[0007] The invention is directed to the aforementioned need in the art, and, as such, provides an efficient catalytic depolymerization reaction that employs mild conditions, wherein production of undesirable byproducts resulting from polymer degradation is minimized. The reaction can be carried out at temperatures of at most 80° C., and, because a nonmetallic catalyst is preferably employed, the depolymerization products, in a preferred embodiment, are substantially free of metal contaminants. With many of the carbene catalysts disclosed herein, the depolymerization reaction can be carried out at a temperature of at most 60° C. or even 30° C. or lower, i.e., at room temperature.
[0008] More specifically, in one aspect of the invention, a method is provided for depolymerizing a polymer having a backbone containing electrophilic linkages, wherein the method involves contacting the polymer with a nucleophilic reagent and a catalyst at a temperature of less than 80° C. An important application of this method is in the depolymerization of polyesters, including homopolymeric polyesters (in which all of the electrophilic linkages are ester linkages) and polyester copolymers (in which a fraction of the electrophilic linkages are ester linkages and the remainder of the electrophilic linkages are other than ester linkages).
[0009] In a related aspect of the invention, a method is provided for depolymerizing a polymer having a backbone containing electrophilic linkages, wherein the method involves contacting the polymer with a nucleophilic reagent and a catalyst that yields depolymerization products that are substantially free of metal contaminants. The polymer may be, for example, a polyester, a polycarbonate, a polyurethane, or a related polymer, in either homopolymeric or copolymeric form, as indicated above. In this embodiment, in order to provide reaction products that are substantially free of contamination by metals and metal-containing compounds, the catalyst used is a purely organic, nonmetallic catalyst. Preferred catalysts herein are carbene compounds, which act as nucleophilic catalysts, as well as precursors to carbene compounds, as will be discussed infra. As is well understood in the art, carbenes are electronically neutral compounds containing a divalent carbon atom with only six electrons in its valence shell. Carbenes include, by way of example, cyclic diaminocarbenes, imidazol-2-ylidenes (e.g., 1,3-dimesityl-imidazol-2-ylidene and 1,3-dimesityl-4,5-dihydroimidazol-2-ylidene), 1,2,4-triazol-3-ylidenes, and 1,3-thiazol-2-ylidenes; see Bourissou et al. (2000) Chem. Rev. 100:39-91.
[0010] Since the initial description of the synthesis, isolation, and characterization of stable carbenes by Arduengo (Arduengo et al. (1991) J. Am. Chem. Soc. 113:361; Arduengo et al. (1992) J. Am. Chem. Soc. 114:5530), the exploration of their chemical reactivity has become a major area of research. See, e.g., Arduengo et al. (1999) Acc. Chem. Res. 32:913; Bourissou et al. (2000), supra; and Brode (1995) Angew. Chem. Int. Ed. Eng. 34:1021. Although carbenes have now been extensively investigated, and have in fact been established as useful in many synthetically important reactions, there has been no disclosure or suggestion to use carbenes as catalysts in nucleophilic depolymerization reactions, i.e., reactions in which a polymer containing electrophilic linkages is depolymerized with a nucleophilic reagent in the presence of a carbene catalyst.
[0011] Suitable catalysts for use herein thus include heteroatom-stabilized carbenes or precursors to such carbenes. The heteroatom-stabilized carbenes have the structure of formula (I)
wherein:
E 1 and E 2 are independently selected from N, NR E , O, P, PR E , and S, R E is hydrogen, heteroalkyl, or heteroaryl, x and y are independently zero, 1, or 2, and are selected to correspond to the valence state of E 1 and E 2 , respectively, and wherein when E 1 and E 2 are other than O or S, then E 1 and E 2 may be linked through a linking moiety that provides a heterocyclic ring in which E 1 and E 2 are incorporated as heteroatoms; R 1 and R 2 are independently selected from branched C 3 -C 30 hydrocarbyl, substituted branched C 3 -C 30 hydrocarbyl, heteroatom-containing branched C 4 -C 30 hydrocarbyl, substituted heteroatom-containing branched C 4 -C 30 hydrocarbyl, cyclic C 5 -C 30 hydrocarbyl, substituted cyclic C 5 -C 30 hydrocarbyl, heteroatom-containing cyclic C 1 -C 30 hydrocarbyl, and substituted heteroatom-containing cyclic C 1 -C 30 hydrocarbyl; L 1 and L 2 are linkers containing 1 to 6 spacer atoms, and are independently selected from heteroatoms, substituted heteroatoms, hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, and substituted heteroatom-containing hydrocarbylene; and m and n are independently zero or I, such that L 1 and L 2 are optional.
[0017] Certain carbene catalysts of formula (I) are novel chemical compounds and are claimed as such herein. These novel carbenes are those wherein a heteroatom is directly bound to E 1 and/or E 2 , and include, solely by way of example, carbenes of formula (I) wherein E 1 is NR E and R E is a heteroalkyl or heteroaryl group such as an alkoxy, alkylthio, aryloxy, arylthio, aralkoxy, or aralkylthio moiety.
[0018] Carbene precursors suitable as catalysts herein include tri-substituted methanes having the structure of formula (PI), metal adducts having the structure of formula (PII), and tetrasubstituted olefins having the structure (PIII)
wherein, in formulae (PI) and (PII):
E 1 and E 2 are independently selected from N, NR E , O, P, PR E , and S, R E is hydrogen, heteroalkyl, or heteroaryl, x and y are independently zero, 1, or 2, and are selected to correspond to the valence state of E 1 and E 2 , respectively, and wherein when E 1 and E 2 are other than O or S, then E 1 and E 2 may be linked through a linking moiety that provides a heterocyclic ring in which E 1 and E 2 are incorporated as heteroatoms; R 1 and R 2 are independently selected from branched C 3 -C 30 hydrocarbyl, substituted branched C 3 -C 30 hydrocarbyl, heteroatom-containing branched C 4 -C 30 hydrocarbyl, substituted heteroatom-containing branched C 4 -C 30 hydrocarbyl, cyclic C 5 -C 30 hydrocarbyl, substituted cyclic C 5 -C 30 hydrocarbyl, heteroatom-containing cyclic C 1 -C 30 hydrocarbyl, and substituted heteroatom-containing cyclic C 1 -C 30 hydrocarbyl; L 1 and L 2 are linkers containing 1 to 6 spacer atoms, and are independently selected from heteroatoms, substituted heteroatoms, hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, and substituted heteroatom-containing hydrocarbylene; m and n are independently zero or 1; R 7 is selected from alkyl, heteroalkyl, aryl, heteroaryl, aralkyl, or heteroaralkyl, substituted with at least one electron-withdrawing substituent; M is a metal; Ln is a ligand; and j is the number of ligands bound to M.
[0028] In compounds of formula (PIII), the substituents are as follows:
E 3 and E 4 are defined as for E 1 and E 2 ; v and w are defined as for x and y; R 8 and R 9 are defined as for R 1 and R 2 ; L 3 and L 4 are defined as for L 1 and L 2 ; and h and k are defined as for m and n.
[0034] The carbene precursors may be in the form of a salt, in which case the precursor is positively charged and associated with an anionic counterion, such as a halide ion (I, Br, Cl), a hexafluorophosphate anion, or the like.
[0035] Novel carbene precursors herein include compounds of formula (PI), those compounds of formula (PII) in which a heteroatom is directly bound to E 1 and/or E 2 , and those compounds of formula (PIII) in which a heteroatom is directly bound to at least one of E 1 , E 2 , E 3 , and E 4 , and may be in the form of a salt as noted above.
[0036] Ideally, the carbene catalyst used in conjunction with the present depolymerization reaction is an N-heterocyclic carbene having the structure of formula (II)
wherein:
R 1 , R 2 , L 1 , L 2 , m, and n are as defined above; and L is a hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, or substituted heteroatom-containing hydrocarbylene linker, wherein two or more substituents on adjacent atoms within L may be linked to form an additional cyclic group.
[0040] As alluded to above, one important application of the present invention is in the recycling of polyesters, including, by way of illustration and not limitation: PET; poly (butylene terephthalate) (PBT); poly(alkylene adipate)s and their copolymers; and poly(ε-caprolactone). The methodology of the invention provides an efficient means to degrade such polymers into their component monomers and/or relatively short oligomeric fragments without need for extreme reaction conditions or metallic catalysts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 illustrates the organocatalytic depolymerization of PET in the presence of excess methanol using N-heterocyclic carbene catalyst, as evaluated in Example 7.
[0042] FIG. 2 illustrates the organocatalytic depolymerization of PET in the presence of ethylene glycol using N-heterocyclic carbene catalyst, as evaluated in Example 6.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Unless otherwise indicated, this invention is not limited to specific polymers, carbene catalysts, nucleophilic reagents, or depolymerization conditions. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.
[0044] As used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a polymer” encompasses a combination or mixture of different polymers as well as a single polymer, reference to “a catalyst” encompasses both a single catalyst as well as two or more catalysts used in combination, and the like.
[0045] In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:
[0046] As used herein, the phrase “having the formula” or “having the structure” is not intended to be limiting and is used in the same way that the term “comprising” is commonly used.
[0047] The term “alkyl” as used herein refers to a linear, branched, or cyclic saturated hydrocarbon group typically although not necessarily containing 1 to about 20 carbon atoms, preferably 1 to about 12 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, octyl, decyl, and the like, as well as cycloalkyl groups such as cyclopentyl, cyclohexyl and the like. Generally, although again not necessarily, alkyl groups herein contain 1 to about 12 carbon atoms. The term “lower alkyl” intends an alkyl group of 1 to 6 carbon atoms, and the specific term “cycloalkyl” intends a cyclic alkyl group, typically having 4 to 8, preferably 5 to 7, carbon atoms. The term “substituted alkyl” refers to alkyl substituted with one or more substituent groups, and the terms “heteroatom-containing alkyl” and “heteroalkyl” refer to alkyl in which at least one carbon atom is replaced with a heteroatom. If not otherwise indicated, the terms “alkyl” and “lower alkyl” include linear, branched, cyclic, unsubstituted, substituted, and/or heteroatom-containing alkyl and lower alkyl, respectively.
[0048] The term “alkylene” as used herein refers to a difunctional linear, branched, or cyclic alkyl group, where “alkyl” is as defined above.
[0049] The term “alkenyl” as used herein refers to a linear, branched, or cyclic hydrocarbon group of 2 to about 20 carbon atoms containing at least one double bond, such as ethenyl, n-propenyl, isopropenyl, n-butenyl, isobutenyl, octenyl, decenyl, tetradecenyl, hexadecenyl, cicosenyl, tetracosenyl, and the like. Preferred alkenyl groups herein contain 2 to about 12 carbon atoms. The term “lower alkenyl” intends an alkenyl group of 2 to 6 carbon atoms, and the specific term “cycloalkenyl” intends a cyclic alkenyl group, preferably having 5 to 8 carbon atoms. The term “substituted alkenyl” refers to alkenyl substituted with one or more substituent groups, and the terms “heteroatom-containing alkenyl” and “heteroalkenyl” refer to alkenyl in which at least one carbon atom is replaced with a heteroatom. If not otherwise indicated, the terms “alkenyl” and “lower alkenyl” include linear, branched, cyclic, unsubstituted, substituted, and/or heteroatom-containing alkenyl and lower alkenyl, respectively.
[0050] The term “alkenylene” as used herein refers to a difunctional linear, branched, or cyclic alkenyl group, where “alkenyl” is as defined above.
[0051] The term “alkoxy” as used herein refers to a group —O-alkyl wherein “alkyl” is as defined above, and the term “alkylthio” as used herein refers to a group —S-alkyl wherein “alkyl is as defined above.
[0052] The term “aryl” as used herein, and unless otherwise specified, refers to an aromatic substituent containing a single aromatic ring or multiple aromatic rings that are fused together, directly linked, or indirectly linked (such that the different aromatic rings are bound to a common group such as a methylene or ethylene moiety). Preferred aryl groups contain 5 to 20 carbon atoms and either one aromatic ring or 2 to 4 fused or linked aromatic rings, e.g., phenyl, naphthyl, biphenyl, and the like, with more preferred aryl groups containing 1 to 3 aromatic rings, and particularly preferred aryl groups containing 1 or 2 aromatic rings and 5 to 14 carbon atoms. “Substituted aryl” refers to an aryl moiety substituted with one or more substituent groups, and the terms “heteroatom-containing aryl” and “heteroaryl” refer to aryl in which at least one carbon atom is replaced with a heteroatom. Unless otherwise indicated, the terms “aromatic,” “aryl,” and “arylene” include heteroaromatic, substituted aromatic, and substituted heteroaromatic species.
[0053] The term “aryloxy” refers to a group —O-aryl wherein “aryl” is as defined above.
[0054] The term “alkaryl” refers to an aryl group with at least one and typically 1 to 6 alkyl, preferably 1 to 3, alkyl substituents, and the term “aralkyl” refers to an alkyl group with an aryl substituent, wherein “aryl” and “alkyl” are as defined above. Alkaryl groups include, for example, p-methylphenyl, 2,4-dimethylphenyl, 2,4,6-trimethylphenyl, and the like. The term “aralkyl” refers to an alkyl group substituted with an aryl moiety, wherein “alkyl” and “aryl” are as defined above.
[0055] The term “alkaryloxy” refers to a group —O—R wherein R is alkaryl, the term “alkarylthio” refers to a group —S—R wherein R is alkaryl, the term aralkoxy refers to a group —O—R wherein R is aralkyl, the term “aralkylthio” refers to a group —S—R wherein R is aralkyl.
[0056] The terms “halo,” “halide,” and “halogen” are used in the conventional sense to refer to a chloro, bromo, fluoro, or iodo substituent. The terms “haloalkyl,” “haloalkenyl,” and “haloalkynyl” (or “halogenated alkyl,” “halogenated alkenyl,” and “halogenated alkynyl”) refer to an alkyl, alkenyl, or alkynyl group, respectively, in which at least one of the hydrogen atoms in the group has been replaced with a halogen atom.
[0057] “Hydrocarbyl” refers to univalent hydrocarbyl radicals containing 1 to about 30 carbon atoms, preferably 1 to about 20 carbon atoms, more preferably 1 to about 12 carbon atoms, including linear, branched, cyclic, saturated, and unsaturated species, such as alkyl groups, alkenyl groups, aryl groups, alkaryl groups, and the like. The term “lower hydrocarbyl” intends a hydrocarbyl group of 1 to 6 carbon atoms, and the term “hydrocarbylene” intends a divalent hydrocarbyl moiety containing 1 to about 30 carbon atoms, preferably 1 to about 20 carbon atoms, most preferably 1 to about 12 carbon atoms, including linear, branched, cyclic, saturated and unsaturated species. The term “lower hydrocarbylene” intends a hydrocarbylene group of 1 to 6 carbon atoms. Unless otherwise indicated, the terms “hydrocarbyl” and “hydrocarbylene” are to be interpreted as including substituted and/or heteroatom-containing hydrocarbyl and hydrocarbylene moieties, respectively.
[0058] The term “heteroatom-containing” as in a “heteroatom-containing alkyl group” (also termed a “heteroalkyl” group) or a “heteroatom-containing aryl group” (also termed a “heteroaryl” group) refers to a molecule, linkage, or substituent in which one or more carbon atoms are replaced with an atom other than carbon, e.g., nitrogen, oxygen, sulfur, phosphorus or silicon, typically nitrogen, oxygen or sulfur. Similarly, the term “heteroalkyl” refers to an alkyl substituent that is heteroatom-containing, the term “heterocyclic” refers to a cyclic substituent that is heteroatom-containing, the terms “heteroaryl” and heteroaromatic” respectively refer to “aryl” and “aromatic” substituents that are heteroatom-containing, and the like. Examples of heteroalkyl groups include alkoxyaryl, alkylsulfanyl-substituted alkyl, N-alkylated amino alkyl, and the like. Examples of heteroaryl substituents include pyrrolyl, pyrrolidinyl, pyridinyl, quinolinyl, indolyl, pyrimidinyl, imidazolyl, 1,2,4-triazolyl, tetrazolyl, etc., and examples of heteroatom-containing alicyclic groups are pyrrolidino, morpholino, piperazino, piperidino, etc. It should be noted that a “heterocyclic” group or compound may or may not be aromatic, and further that “heterocycles” may be monocyclic, bicyclic, or polycyclic as described above with respect to the term “aryl.”
[0059] By “substituted” as in “substituted hydrocarbyl,” “substituted alkyl,” “substituted aryl,” and the like, as alluded to in some of the aforementioned definitions, is meant that in the hydrocarbyl, alkyl, aryl, or other moiety, at least one hydrogen atom bound to a carbon (or other) atom is replaced with a non-hydrogen substituent. Examples of such substituents include, without limitation, functional groups such as halide, hydroxyl, sulfhydryl, C 1 -C 20 alkoxy, C 5 -C 20 aryloxy, C 2 -C 20 acyl (including C 2 -C 20 alkylcarbonyl (—CO-alkyl) and C 6 -C 20 arylcarbonyl (—CO-aryl)), acyloxy (—O-acyl), C 2 -C 20 alkoxycarbonyl (—(CO)-O-alkyl), C 6 -C 20 aryloxycarbonyl (—(CO)-O-aryl), halocarbonyl (—CO)—X where X is halo), C 2 -C 20 alkyl-carbonato (—O—(CO)—O-alkyl), C 6 -C 20 arylcarbonato (—O—(CO)—O-aryl), carboxy (—COOH), carboxylato (—COO − ), carbamoyl (—(CO)—NH 2 ), mono-(C 1 -C 20 alkyl)-substituted carbamoyl (—(CO)—NH(C 1 -C 20 alkyl)), di-(C 1 -C 20 alkyl)-substituted carbamoyl —(CO)—N(C 1 -C 20 alkyl) 2 ), mono-substituted arylcarbamoyl (—(CO)—NH-aryl), thiocarbamoyl (—(CS)—NH 2 ), carbamido (—NH—(CO)—NH 2 ), cyano(—C≡N), cyanato (—O—C≡N), formyl (—(CO)—H), thioformyl (—(CS)—H), amino (—NH 2 ), mono- and di-(C 1 -C 20 alkyl)-substituted amino, mono- and di-(C 5 -C 20 aryl)-substituted amino, C 2 -C 20 alkylamido (—NH—(CO)-alkyl), C 6 -C 20 arylamido (—NH—(CO)-aryl), imino (—CR═NH where R=hydrogen, C 1 -C 20 alkyl, C 5 -C 20 aryl, C 6 -C 24 alkaryl, C 6 -C 24 aralkyl, etc.), alkylimino (—CR═N(alkyl), where R=hydrogen, alkyl, aryl, alkaryl, etc.), arylimino (—CR═N(aryl), where R=hydrogen, alkyl, aryl, alkaryl, etc.), nitro (—NO 2 ), nitroso (—NO), sulfo (—SO 2 —OH), sulfonato (—SO 2 —O − ), C 1 -C 20 alkylsulfanyl (—S-alkyl; also termed “alkylthio”), arylsulfanyl (—S-aryl; also termed “arylthio”), C 1 -C 20 alkylsulfinyl (—(SO)-alkyl), C 5 -C 20 arylsulfinyl (—(SO)-aryl), C 1 -C 20 alkylsulfonyl (—SO 2 -alkyl), C 5 -C 20 arylsulfonyl (—SO 2 -aryl), and thiocarbonyl (═S); and the hydrocarbyl moieties C 1 -C 20 alkyl (preferably C 1 -C 18 alkyl, more preferably C 1 -C 12 alkyl, most preferably C 1 -C 6 alkyl), C 2 -C 20 alkenyl (preferably C 2 -C 18 alkenyl, more preferably C 2 -C 12 alkenyl, most preferably C 2 -C 6 alkenyl), C 2 -C 20 alkynyl (preferably C 2 -C 18 alkynyl, more preferably C 2 -C 12 alkynyl, most preferably C 2 -C 6 alkynyl), C 5 -C 20 aryl (preferably C 5 -C 14 aryl), C 6 -C 24 alkaryl (preferably C 6 -C 18 alkaryl), and C 6 -C 24 aralkyl (preferably C 6 -C 18 aralkyl).
[0060] In addition, the aforementioned functional groups may, if a particular group permits, be further substituted with one or more additional functional groups or with one or more hydrocarbyl moieties such as those specifically enumerated above. Analogously, the above-mentioned hydrocarbyl moieties may be further substituted with one or more functional groups or additional hydrocarbyl moieties such as those specifically enumerated.
[0061] By “substantially free of” a particular type of chemical compound is meant that a composition or product contains less 10 wt. % of that chemical compound, preferably less than 5 wt. %, more preferably less than 1 wt. %, and most preferably less than 0.1 wt. %. For instance, the depolymerization product herein is “substantially free of” metal contaminants, including metals per se, metal salts, metallic complexes, metal alloys, and organometallic compounds.
[0062] “Optional” or “optionally” means that the subsequently described circumstance may or may not occur, so that the description includes instances where the circumstance occurs and instances where it does not. For example, the phrase “optionally substituted” means that a non-hydrogen substituent may or may not be present on a given atom, and, thus, the description includes structures wherein a non-hydrogen substituent is present and structures wherein a non-hydrogen substituent is not present.
[0063] Accordingly, the invention features a method for depolymerizing a polymer having a backbone containing electrophilic linkages. The electrophilic linkages may be, for example, ester linkages (—(CO)—O—), carbonate linkages (—O—(CO)—O)—, urethane linkages (—O—(CO)—NH), substituted urethane linkages (—O—(CO)—NR—, where R is a nonhydrogen substituent such as alkyl, aryl, alkaryl, or the like), amido linkages (—(CO)—NH—), substituted amido linkages (—(CO)—NR— where R is as defined previously, thioester linkages (—(CO)—S—), sulfonic ester linkages (—S(O) 2 —O—), and the like. Other electrophilic linkages that can be cleaved using nucleophilic reagents will be known to those of ordinary skill in the art of organic chemistry and polymer science and/or can be readily found by reference to the pertinent texts and literature. The polymer undergoing depolymerization may be linear or branched, and may be a homopolymer or copolymer, the latter including random, block, multiblock, and alternating copolymers, terpolymers, and the like. Examples of polymers that can be depolymerized using the methodology of the invention include, without limitation:
poly(alkylene terephthalates) such as fiber-grade PET (a homopolymer made from monoethylene glycol and terephthalic acid), bottle-grade PET (a copolymer made based on monoethylene glycol, terephthalic acid, and other comonomers such as isophthalic acid, cyclohexene dimethanol, etc.), poly (butylene terephthalate) (PBT), and poly(hexamethylene terephthalate); poly(alkylene adipates) such as poly(ethylene adipate), poly(1,4-butylene adipate), and poly(hexamethylene adipate); poly(alkylene suberates) such as poly(ethylene suberate); poly(alkylene sebacates) such as poly(ethylene sebacate); poly(c-caprolactone) and poly(β-propiolactone); poly(alkylene isophthalates) such as poly(ethylene isophthalate); poly(alkylene 2,6-naphthalene-dicarboxylates) such as poly(ethylene 2,6-naphthalene-dicarboxylate); poly(alkylene sulfonyl-4,4′-dibenzoates) such as poly(ethylene sulfonyl-4,4′-dibenzoate); poly(p-phenylene alkylene dicarboxylates) such as poly(p-phenylene ethylene dicarboxylates); poly(trans-1,4-cyclohexanediyl alkylene dicarboxylates) such as poly(trans-1,4-cyclohexanediyl ethylene dicarboxylate); poly(1,4-cyclohexane-dimethylene alkylene dicarboxylates) such as poly(1,4-cyclohexane-dimethylene ethylene dicarboxylate); poly([2.2.2]-bicyclooctane-1,4-dimethylene alkylene dicarboxylates) such as poly([2.2.2]-bicyclooctane-1,4-dimethylene ethylene dicarboxylate); lactic acid polymers and copolymers such as (S)-polylactide, (R,S)-polylactide, poly(tetramethylglycolide), and poly(lactide-co-glycolide); and polycarbonates of bisphenol A, 3,3′-dimethylbisphenol A, 3,3′,5,5′-tetrachlorobisphenol A, 3,3′,5,5′-tetramethylbisphenol A; polyamides such as poly(p-phenylene terephthalamide) (Kevlaro); poly(alkylene carbonates) such as poly(propylene carbonate); polyurethanes such as those available under the tradenames Baytece and Bayfil®, from Bayer Corporation; and polyurethane/polyester copolymers such as that available under the tradename Bayda®, from Bayer Corporation.
[0082] Depolymerization of the polymer is carried out, as indicated above, in the presence of a nucleophilic reagent and a catalyst. Nucleophilic reagents, as will be appreciated by those of ordinary skill in the art, include monohydric alcohols, diols, polyols, thiols, primary amines, and the like, and may contain a single nucleophilic moiety or two or more nucleophilic moieties, e.g., hydroxyl, sulfhydryl, and/or amino groups. The nucleophilic reagent is selected to correspond to the particular electrophilic linkages in the polymer backbone, such that nucleophilic attack at the electrophilic linkage results in cleavage of the linkage. For example, a polyester can be cleaved at the ester linkages within the polymer backbone using an alcohol, preferably a primary alcohol, most preferably a C 2 -C 4 monohydric alcohol such as ethanol, isopropanol, and t-butyl alcohol. It will be appreciated that such a reaction cleaves the ester linkages via a transesterification reaction, as will be illustrated infra.
[0083] The preferred catalysts for the depolymerization reaction are carbenes and carbene precursors. Carbenes include, for instance, diarylcarbenes, cyclic diaminocarbenes, imidazol-2-ylidenes, 1,2,4-triazol-3-ylidenes, 1,3-thiazol-2-ylidenes, acyclic diaminocarbenes, acyclic aminooxycarbenes, acyclic aminothiocarbenes, cyclic diborylcarbenes, acyclic diborylcarbenes, phosphinosilylcarbenes, phosphinophosphoniocarbenes, sulfenyl-trifluoromethylcarbene, and sulfenyl-pentafluorothiocarbene. See Bourissou et al. (2000), cited supra. Preferred carbenes are heteroatom-stabilized carbenes and preferred carbene precursors are precursors to heteroatom-stabilized carbenes. nitrogen-containing carbenes, with N-heterocyclic carbenes most preferred.
[0084] In one embodiment, heteroatom-stabilized carbenes suitable as depolymerization catalysts herein have the structure of formula (I)
wherein the various substituents are as follows:
[0086] E 1 and E 2 are independently selected from N, NR E , O, P, PR E , and S, R E is hydrogen, heteroalkyl, or heteroaryl, and x and y are independently zero, 1, or 2, and are selected to correspond to the valence state of E 1 and E 2 , respectively. When E 1 and E 2 are other than O or S, then E 1 and E 2 may be linked through a linking moiety that provides a heterocyclic ring in which E 1 and E 2 are incorporated as heteroatoms. In the latter case, the heterocyclic ring may be aliphatic or aromatic, and may contain substituents and/or heteroatoms. Generally, such a cyclic group will contain 5 or 6 ring atoms.
[0087] For example, in representative compounds of formula (I):
(1) E 1 is O or S and x is 1; (2) E 1 is N, x is 1, and E 1 is linked to E 2 ; (3) E 1 is N, x is 2, and E 1 and E 2 are not linked; (4) E 1 is NR E , x is 1, and E 1 and E 2 are not linked; or (5) E 1 is NR E , x is zero, and E 1 is linked to E 2 .
[0093] R 1 and R 2 are independently selected from branched C 3 -C 30 hydrocarbyl, substituted branched C 3 -C 30 hydrocarbyl, heteroatom-containing branched C 4 -C 30 hydrocarbyl, substituted heteroatom-containing branched C 4 -C 30 hydrocarbyl, cyclic C 5 -C 30 hydrocarbyl, substituted cyclic C 5 -C 30 hydrocarbyl, heteroatom-containing cyclic C 1 -C 30 hydrocarbyl, and substituted heteroatom-containing cyclic C 1 -C 30 hydrocarbyl. Preferably, at least one of R 1 and R 2 , and more preferably both R 1 and R 2 , are relatively bulky groups, particularly branched alkyl (including substituted and/or heteroatom-containing alkyl), aryl (including substituted aryl, heteroaryl, and substituted heteroaryl), alkaryl (including substituted and/or heteroatom-containing aralkyl), and alicyclic. Using such sterically bulky groups to protect the highly reactive carbene center has been found to kinetically stabilize singlet carbenes, which are preferred reaction catalysts herein. Particular sterically bulky groups that are suitable as R 1 and R 2 are optionally substituted and/or heteroatom-containing C 3 -C 12 alkyl, tertiary C 4 -C 12 alkyl, C 5 -C 12 aryl, C 6 -C 18 alkaryl, and C 5 -C 12 alicyclic, with C 5 -C 12 aryl and C 6 -C 12 alkaryl particularly preferred. The latter substituents are exemplified by phenyl optionally substituted with 1 to 3 substituents selected from lower alkyl, lower alkoxy, and halogen, and thus include, for example, p-methylphenyl, 2,6-dimethylphenyl, and 2,4,6-trimethylphenyl (mesityl).
[0094] L 1 and L 2 are linkers containing 1 to 6 spacer atoms, and are independently selected from heteroatoms, substituted heteroatoms, hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, and substituted heteroatom-containing hydrocarbylene; and m and n are independently zero or 1, meaning that each of L 1 and L 2 is optional. Preferred L 1 and L 2 moieties include, by way of example, alkylene, alkenylene, arylene, aralkylene, any of which may be heteroatom-containing and/or substituted, or L 1 and/or L 2 may be a heteroatom such as O or S, or a substituted heteroatom such as NH, NR (where R is alkyl, aryl, other hydrocarbyl, etc.), or PR; and
[0095] In one preferred embodiment, E 1 and E 2 are independently N or NR E and are not linked, such that the carbene is an N-heteroacyclic carbene. In another preferred embodiment, E 1 and E 2 are N, x and y are 1, and E 1 and E 2 are linked through a linking moiety such that the carbene is an N-heterocyclic carbene. N-heterocyclic carbenes suitable herein include, without limitation, compounds having the structure of formula (II)
wherein R 1 , R 2 , L 1 , L 2 , m, and n are as defined above for carbenes of formula (I). In carbenes of structural formula (II), L is a hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, or substituted heteroatom-containing hydrocarbylene linker, wherein two or more substituents on adjacent atoms within L may be linked to form an additional cyclic group. L is a hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, or substituted heteroatom-containing hydrocarbylene linker, wherein two or more substituents on adjacent atoms within L may be linked to form an additional cyclic group. For example, L may be —CR 3 R 4 —CR 5 R 6 — or —CR 3 ═CR 5 —, wherein R 3 , R 4 , R 5 , and R 6 are independently selected from hydrogen, halogen, C 1 -C 12 alkyl, or wherein any two of R 3 , R 4 , R 5 , and R 6 may be linked together to form a substituted or unsubstituted, saturated or unsaturated ring.
[0097] Accordingly, when L is —CR 3 R 4 —CR 5 R 6 — or —CR 3 ═CR 5 —, the carbene has the structure of formula (II)
in which q is an optional double bond, s is zero or 1, and t is zero or 1, with the proviso that when q is present, s and t are zero, and when q is absent, s and t are 1.
[0099] Certain carbenes are new chemical compounds and are claimed as such herein. These are compounds having the structure of formula (I) wherein a heteroatom is directly bound to E 1 and/or E 2 . e.g., with the proviso that a heteroatom is directly bound to E 1 , E 2 , or to both E 1 and E 2 , and wherein the carbene may be in the form of a salt (such that it is positively charged and associated with a negatively charged counterion). These novel carbenes are those wherein a heteroatom is directly bound to E 1 and/or E 2 , and include, solely by way of example, carbenes of formula (I) wherein E 1 and/or E 2 is NR E and R E is a heteroalkyl or heteroaryl group such as an alkoxy, alkylthio, aryloxy, arylthio, aralkoxy, or aralkylthio moiety. Other such carbenes are those wherein x and/or y is at least 1, and L 1 and/or L 2 is heteroalkyl, heteroaryl, or the like, wherein the heteroatom within L 1 and/or L 2 is directly bound to E 1 and/or E 2 , respectively.
[0100] Representative of such novel carbenes are compounds of formula (I) wherein E 1 is NR E , and R E is alkoxy, substituted alkoxy, aryloxy, substituted aryloxy, aralkoxy, or substituted aralkoxy. A preferred subset of such carbenes are those wherein E 2 is N, x is zero, y is 1, and E 1 and E 2 are linked through a substituted or unsubstituted lower alkylene or lower alkenylene linkage. A more preferred subset of such carbenes are those wherein R E is lower alkoxy or monocyclic aryl-substituted lower alkoxy, E 1 and E 2 are linked through a moiety —CR 3 R 4 —CR 5 R 6 — or —CR 3 ═CR 5 —, wherein R 3 , R 4 , R 5 , and R 6 are independently selected from hydrogen, halogen, and C 1 -C 12 alkyl, n is 1, L 2 is lower alkylene, and R 2 is monocyclic aryl or substituted monocyclic aryl. Examples 8-11 describe syntheses of representative compounds within this group.
[0101] As indicated previously, suitable catalysts for the present depolymerization reaction are also precursors to carbenes, preferably precursors to N-heterocyclic and N-heteroacyclic carbenes. In one embodiment, the precursor is a tri-substituted methane compound having the structure of formula (PI)
wherein E 1 , E 2 , x, y, R 1 , R 2 , L 1 , L 2 , m, and n are as defined for carbenes of structural formula (I), and wherein R 7 is selected from alkyl, heteroalkyl, aryl, heteroaryl, aralkyl, or heteroaralkyl, and is substituted with at least one electron-withdrawing substituent such as
[0103] fluoro, fluoroalkyl (including perfluoroalkyl), chloro, nitro, acytyl. It will be appreciated that the foregoing list is not exhaustive and that any electron-withdrawing group may serve as a substituent providing that the group does not cause unwanted interaction of the catalyst with other components of the depolymerization mixture or adversely affect the depolymerization reaction in any way. Specific examples of R 7 groups thus include p-nitrophenyl, 2,4-dinitrobenzyl, 1,1,2,2-tetrafluoroethyl, pentafluorophenyl, and the like.
[0104] Catalysts of formula (PI) are new chemical entities. Representative syntheses of such compounds are described in Examples 13 and 14 herein. As may be deduced from those examples, compounds of formula (PI) wherein E 1 and E 2 are N may be synthesized from the corresponding diamine and an appropriately substituted aldehyde.
[0105] Another carbene precursor useful as a catalyst in the present depolymerization reaction has the structure of formula (PII)
wherein E 1 , E 2 , x, y, R 1 , R 2 , L 1 , L 2 , m, and n are as defined for carbenes of structural formula (I), M is a metal, e.g., gold, silver, other main group metals, or transition metals, with Ag, Cu, Ni, Co, and Fe generally preferred, and Ln is a ligand, generally an anionic or neutral ligand that may or may not be the same as -E 1 -[(L 1 ) m -R 1 ] x or -E 2 -[(L 2 ) n -R 2 ] y . Generally, carbene precursors of formula (PII) can be synthesized from a carbene salt and a metal oxide; see, e.g., the synthesis described in detail in Example 12.
[0107] Still another carbene precursor suitable as a depolymerization catalyst herein is a tetrasubstituted olefin having the structure of formula (PIII)
wherein: E 1 , E 2 , x, y, R 1 , R 2 , L 1 , L 2 , m, and n are defined as for carbenes of structural formula (I); E 3 and E 4 are defined as for E 1 and E 2 ; v and w are defined as for x and y; R 8 and R 9 are defined as for R 1 and R 2 ; L 3 and L 4 are defined as for L 1 and L 2 ; and h and k are defined as for m and n. These olefins are readily formed from N,N-diaryl- and N,N-dialkyl-N-heterocyclic carbene salts and a strong base, typically an inorganic base such as a metal alkoxide.
[0109] As with the carbenes per se, those catalyst precursors having the structure of formula (PII) or (PIII) in which a heteroatom is directly bound to an “E” moiety, i.e., to E 1 , E 2 , E 3 , and/or E 4 , are new chemical entities. Preferred such precursors are those wherein the “E” moieties are NR E or linked N atoms, and the directly bound heteroatom within R E is oxygen or sulfur.
[0110] The depolymerization reaction may be carried out in an inert atmosphere by dissolving a catalytically effective amount of the selected catalyst in a solvent, combining the polymer and the catalyst solution, and then adding the nucleophilic reagent. In a particularly preferred embodiment, however, the polymer, the nucleophilic reagent, and the catalyst (e.g., a carbene or a carbene precursor) are combined and dissolved in a suitable solvent, and depolymerization thus occurs in a one-step reaction.
[0111] Preferably, the reaction mixture is agitated (e.g., stirred), and the progress of the reaction can be monitored by standard techniques, although visual inspection is generally sufficient, insofar as a transparent reaction mixture indicates that the polymer has degraded to an extent sufficient to allow all degradation products to go into solution. Examples of solvents that may be used in the polymerization reaction include organic, protic, or aqueous solvents that are inert under the depolymerization conditions, such as aromatic hydrocarbons, chlorinated hydrocarbons, ethers, aliphatic hydrocarbons, or mixtures thereof. Preferred solvents include toluene, methylene chloride, tetrahydrofuran, methyl t-butyl ether, Isopar, gasoline, and mixtures thereof. Supercritical fluids may also be used as solvents, with carbon dioxide representing one such solvent. Reaction temperatures are in the range of about 0° C. to about 100° C. , typically at most 80° C., preferably 60° C. or lower, and most preferably 30° C. or less, and the reaction time will generally be in the range of about 12 to 24 hours. Pressures range from atmospheric to pressures typically used in conjunction with supercritical fluids, with the preferred pressure being atmospheric.
[0112] It is to be understood that while the invention has been described in conjunction with the preferred specific embodiments thereof, that the foregoing description as well as the examples that follow are intended to illustrate and not limit the scope of the invention. Other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.
[0113] All patents, patent applications, and publications mentioned herein are hereby incorporated by reference in their entireties.
[heading-0114] Experimental:
[0115] General Procedures. 1 H and 13 C NMR spectra were recorded on a Bruke-Avance (400 MHz for 1 H and 100 MHz for 13 C). All NMR spectra were recorded in CDCl 3 . Materials. Solvents were obtained from Sigma-Aldrich and purified by distillation. Other reagents were obtained commercially or synthesized as follows: poly(propylene carbonate), poly(bisphenol A carbonate), poly(1,4-butylene adipate), 1-ethyl-3-methyl-1-H-imidazolium chloride, ethylene glycol, butane-2,3-dione monooxime, ammonium hexafluorophosphate, pentafluorobenzaldehyde, and mesityl diamine, obtained from Sigma-Aldrich; 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidene, synthesized according to the method of Arduengo et al. (1999) Tetrahedron 55:14523; N,N-diphenyl imidazoline, chloride salt, synthesized according to the method of Wanzlick et al. (1961) Angew. Chem. 73:493 and Wanzlick et al. (1962) Angew. Chem. 74:128, and Wanzlick et al. (1963) Chem. Ber. 96:3024; 1,3,5-tribenzyl-[1,3,5]triazinane, synthesized according to the method of Arduengo et al. (1992) J. Am. Chem. Soc. 114:5530, cited supra.
EXAMPLE 1
[0116] Depolymerization of Poly(propylene carbonate) (M w =50,000) with isolated carbene: 7 mg (0.02 mmol) of 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidene dissolved in toluene (0.6 mL), was added to a stirred mixture of 0.5 g of poly(propylene carbonate) in toluene (10 mL), under N 2 . After stirring for 5 minutes at room temperature, 2 mL of methanol were added to the reaction mixture and the temperature was brought to 80° C. Stirring was continued for 3 hours followed by the evaporation of the solvent in vacuo. The 1 H and 13 C NMR spectra showed the presence of a single monomer, 4-methyl-[1,3]-dioxolan-2-one. However, there were 4 peaks in the GC-MS.
[heading-0117] GC-MS:
[0118] a) m/z (5%) 5.099 min=106 (42), 103 (5), 91 (100), 77 (8), 65 (8)
[0119] b) m/z (5%) 5.219 min=106 (60), 105 (30), 103 (8), 91 (100), 77 (8), 65 (5), 51 (5)
[0120] c) m/z (85%) 6.750 min=102 (15), 87 (40), 58 (20), 57 (100). Major product.
[0121] d) m/z (5%) 9.030 min=136(10), 135 (100), 134 (70), 120 (85), 117 (8), 103 (5), 91 (14), 77 (10), 65 (5).
[0122] 1 H NMR :1.4 (d, 3H), 3.9 (t, 1H), 4.5 (t, 1H), 4.8 (m, 1H).
[0123] 13 C NMR: 18.96, 70.42, 73.43, 154.88
EXAMPLE 2
[0124] Depolymerization of Poly(Bisphenol A carbonate) (M w =65,000) with isolated carbene: 7 mg (0.02 mmol) of 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidine dissolved in toluene (1 mL), was added to a stirred mixture of 0.5 g of poly(bisphenol A carbonate) in toluene (10 mL), under N 2 . After stirring for 5 minutes at room temperature, 2 mL of methanol were added to the reaction mixture. The temperature was brought to 80° C. and stirring was continued for 18 hours followed by the evaporation of the solvent in vacuo. The 1 H and 13 C NMR spectra showed the presence of two compounds identified as, bisphenol A and carbonic acid 4-[1-hydroxy-phenyl)-1-methyl-ethyl]-phenyl ester 4-[1-(4-methoxy-phenyl)-1-methyl-ethyl] phenyl ester. However, GC-MS indicated 4 peaks.
[heading-0125] GC-MS:
[0126] a) m/z (5%) 5.107 min=106 (40), 103 (5), 91 (100), 77 (8), 65 (8), 51 (8)
[0127] b) m/z (5%) 5.210 min=106 (60), 105 (30), 103 (8), 91 (100), 77 (8), 65 (5), 51 (5)
[0128] c) m/z (60%) 14.301 min=228 (30), 213 (100), 119 (15), 91 (10). Major product
[0129] d) m/z (30%) 16.016 min=495 (30), 333 (10), 319 (20), 299 (5), 281 (5), 259 (25), 239 (38), 197 (40), 181 (12), 151 (12), 135 (100), 119 (10), 91 (10).
[0130] 1 H NMR: 1.6-1.8 (m), 2,4 (s), 3.96 (s), 6.7-6.8 (t), 7.0-7.3 (m).
EXAMPLE 3
[0131] Depolymerization of Poly(1,4-butylene adipate) (M n =12,000) with isolated carbene: 0.006 g (0.02 mmol) of 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidine dissolved in toluene (1 mL), was added to a stirred mixture of 1.0 g of poly(1,4-butylene adipate) in toluene (10 mL), under N 2 . After stirring for 5 minutes at room temperature, 2 mL of methanol were added to the reaction mixture. The temperature was brought to 80° C. and stirring was continued for 6 hours followed by the evaporation of the solvent in vacuo. The
[0132] 1 H and 13 C NMR showed the presence of a single product, and the GC-MS showed two products.
[heading-0133] GC-MS:
[0134] a) m/z (95%) 5.099 min=143 (80), 142 (20), 115 (20), 114 (100), 111 (70), 101 (65), 87 (12), 83 (25), 82 (12), 74 (36), 73 (26), 69 (10), 59 (72), 55 (60). Major product.
[0135] b) m/z (5%) 12.199 min=201 (4), 161 (6), 143 (100), 129 (32), 116 (12), 115 (25), 111 (70), 101 (12), 87 (10), 83 (15), 73 (34), 71 (12), 59 (14), 55 (42).
[0136] 1 H NMR :1.67 (m), 2.32 (s), 4.08 (s).
[0137] 13 C NMR: 24.26, 25.18, 33.74, 63.75, 173.23
EXAMPLE 4
[0138] Depolymerization of Poly(propylene carbonate) (M w =50,000) with in-situ carbene: To a mixture of 7 mg (0.047 mmol) of 1-ethyl-3-methyl-1-H-imidazolium chloride in tetrahydrofuran (THF) was added 4 mg (0.038 mmol) of potassium t-butoxide (t-BOK), under N 2 . After 30 min stirring, 0.1 mL of the reaction mixture was transferred to a flask that was charged with 0.5 g of poly(propylene carbonate) in 10 mL of THF. The reaction mixture was stirred for 10 min at room temperature followed by the addition of 2 mL of methanol. Stirring was continued at room temperature for 3 hours. Solvent was removed and the 1 H and 13 C NMR spectra showed the presence of a single product, 4-methyl-[1,3]-dioxolan-2-one. However, before the removal of the solvent the GC-MS of the crude reaction mixture showed 6 different compounds.
[heading-0139] GC-MS:
[0140] a) m/z (15%) 6.268 min=119 (4), 90 (100), 75 (4), 59 (25).
[0141] b) m/z (5%) 6.451 min=104 (40), 103 (30), 90 (5), 77 (5), 59 (100), 58 (10), 57 (10).
[0142] c) m/z (70%) 6.879 min=102 (10), 87 (25), 58 (14), 57 (100). Major product.
[0143] d) m/z (1%) 7.565 min=103 (40), 89 (5), 59 (100), 58 (5), 57 (8).
[0144] e) m/z (4%) 8.502 min=207 (14), 133 (10), 103 (35), 90 (10), 89 (10), 59 (100) 58 (12), 57 (14).
[0145] f) m/z (5%) 8.936 min=148 (8), 118 (8), 117 (15), 103 (20), 77 (60), 72 (8), 59 (100), 58 (5), 57 (5).
[0146] 1 H NMR :1.4 (d, 3H), 3.9 (t, 1H), 4.5 (t, 1H), 4.8 (m, 1H).
[0147] 13 C NMR: 18.96, 70.42, 73.43, 154.88
EXAMPLE 5
[0148] Depolymerization of Poly(bisphenol A carbonate) (M w =65,000) with in situ carbene: To a mixture of 7 mg (0.047 mmol) of 1-ethyl-3-methyl-1-H-imidazolium chloride in THF (1 mL) was added 4 mg (0.038 mmol) of t-BOK, under N 2 . After 30 min, stirring 0.1 mL of the reaction mixture was transferred to a flask that was charged with 0.5 g of poly(bisphenol A carbonate) in 10 mL of THF. The reaction mixture was stirred for 10 min at room temperature followed by the addition of 2 mL of methanol. Stirring was continued at room temperature for 3 hours. The solvent was removed in vacuo and the 1 H, 13 C NMR and GC-MS spectra showed a mixture of monomer and oligomers, where the major product was bisphenol A.
[heading-0149] GC-MS:
[0150] a) m/z (10%) 12.754 min=212 (30), 198 (20), 197 (100), 182 (10), 181 (10), 179 (10), 178 (10), 165 (8), 152 (8), 135 (10), 119 (12), 103 (15), 91 (12), 77 (10), 65 (5).
[0151] b) m/z (5%) 13.674 min=282 (5), 281 (10), 255 (8), 229 (10), 228 (40), 214 (20), 213 (100), 208 (30), 197 (30), 191 (5), 181 (5), 179 (5), 165 (10), 152 (8), 135 (25), 134 (25), 133 (5), 120 (5), 119 (50), 115 (10), 103 (10), 99 (5), 97 (5), 96 (5), 91 (30), 79 (5), 77 (10), 65 (8).
[0152] c) m/z (35%) 14.286 min=228 (34), 214 (20), 213 (100), 197 (5), 165 (5), 135 (5), 119 (20), 107 (5), 91 (10), 77 (5), 65 (5). Major Product.
[0153] d) m/z (35%) 15.189 min=286 (20), 272 (15), 271 (100), 227 (5), 212 (5), 197 (3), 183 (2), 169 (3), 133 (3), 119 (5).
[0154] e) m/z (10%) 15.983 min=344 (20), 330 (20), 329 (100), 285 (5), 269 (3), 226 (3), 211 (2), 183 (3), 165 (3), 153 (2), 133 (6), 121 (2), 91 (2), 77 (1), 59 (3).
[0155] Depolymerization of PET according to the above scheme: 20 mg of t-BOK and 45 mg of N,N-diphenyl imidazoline, chloride salt, were placed in a vial with 2 mL THF and stirred for 15 minutes. Ethylene glycol (2.3 g) and PET (0.25 g) (pellets obtained from Aldrich dissolved in CHCl 3 and trifluoroacetic acid and precipitated with methanol to form a white powder) were combined to form a PET slurry. The catalyst was added to the slurry with approximately 5 additional mL THF. After 2 hours, the solution became more transparent, indicating dissolution of the components of the depolymerization mixture. The admixture was stirred overnight, yielding a completely clear solution the following day. the THF was removed, yielding 225 mg of white solid. 1 H NMR 13 C NMR, and GC-MS were all consistent with bis(hydroxy ethylene) terephthalate.
[0156] Depolymerization of PET according to the above scheme: 25 mg of 1,3-dimethyl imidazole, iodide salt, and 11 mg of t-BOK were placed in a vial with 2 mL of THF and stirred for 15 min. Methanol (3.11 g) and PET (308 mg, as in Example 6) were combined with 5 mL of THF to form an insoluble mixture. The catalyst mixture was filtered into the PET/methanol mixture. After 1 hour, there was a noticeable increase in transparency. After 14 hours, the solution was completely homogeneous and clear. The solvent was removed by rotary evaporation to yield a white crystalline product (250 mg). 1 H NMR indicated complete conversion to dimethyl terephthalate.
[0157] Examples 6 and 7 may be better understood by reference to the synthetic route used to prepare the PET and the possible depolymerization products obtained therefrom. The PET obtained in each example was prepared by synthesis according to a two-step transesterification process from dimethyl teraphthalate (DMT) and excess ethylene glycol (EO) in the presence of a metal alkanoate or acetate of calcium, zinc, manganese, titanium etc. The first step generates bis(hydroxy ethylene) teraphthalate (BHET) with the elimination of methanol and the excess EO. The BHET is heated, generally in the presence of a transesterification catalyst, to generate high polymer. This process is generally accomplished in a vented extruder to remove the polycondensate (EO) and generate the desired thermoformed object from a low viscosity precursor. The reaction takes place according to the following scheme:
[0158] The different options for chemical recycling are regeneration of the base monomers (DMT and EG), glycolysis of PET back to BHET, decomposition of PET with propylene glycol and reaction of the degradation product with maleic anhydride to form “unsaturated polyesters” for fiber reinforced composites and decomposition with glycols, followed by reaction with dicarboxylic acids to produce polyols for urethane foam and elastomers.
[0159] In Example 7, PET powder was slurried in a THF/methanol solvent mixture. N-heterocyclic carbene (3-5 mol %), generated in situ, was added and within approximately 3 hours the PET went into solution. Anaylsis of the degradation product indicated quantitative consumption of PET and depolymerization via transesterification to EO and DMT. The DMT is readily recovered by recrystallization, while EO can be recovered by distillation ( FIG. 1 ). Alternatively, and as established in Example 6, if EO is used as the alcohol (˜50 to 200 mol % excess) in the THF slurry, the depolymerization product is BHET, which is the most desirable and can be directly recycled via conventional methods to PET ( FIG. 2 ). The N-heterocyclic carbene catalyst platform is extremely powerful, as the nature of the substituents has a pronounced effect on catalyst stability and activity towards different substrates.
[0160] The PET depolymerization reactions of Examples 6 and 7 are illustrated schematically below.
[0161] The following Examples 8-11 describe synthesis of new carbcne precursors as illustrated in the following scheme:
EXAMPLE 8
[0162] 3-Benzyl-1-methoxy-4,5-dimethylimidazolium iodide (2): Methyl iodide (0.5 mL, 7.8 mmol) was added via syringe to a solution of imidazole-N-oxide 1 (1.0 g, 4.9 mmol) in ca. 20 mL of CHCl 3 (compound 1 was prepared from 1,3,5-tribenzyl-[1,3,5]triazinane and butane-2,3-dione monooxime using the procedure of Arduengo et al. (1992), supra.) The resulting mixture was stirred at room temperature overnight. Removal of the volatiles in vacuo afforded a thick yellow oil of suitable purity in an undetermined yield. 1 H-NMR (δ, CDCl 3 ): 10.32 (s, 1H, N—CH—N); 7.39 (m, 5H, C 6 H 5 ); 5.56 (s, 2H, NCH 2 ); 4.38 (s, 3H, OCH 3 ); 2.27 (s, 3H, CH 3 ); 2.20 (s, 3H, CH 3 ).
EXAMPLE 9
[0163] 3-Benzyl-1-methoxy-4,5-dimethylimidazolium hexafluorophosphate (3): Crude iodide 2 was taken up in deionized (DI) water, which separated the product from small amounts of a dark, insoluble residue. The water solution was decanted to a second flask and a solution of ammonium hexafluorophosphate (950 mg, ca. 5.8 mmol) in 10 mL of DI water was added in portions. An oil separated during the addition, and the supernatant solution was decanted out. The oil was crushed in cold (0° C.), and subsequently recrystallized in methanol. Yield: 1.3 g (73% from 1). 1 H-NMR (δ, CDCl 3 ): 8.67 (s, 1H, N—CH—N); 7.39 (m, 3H, C 6 H 5 ); 7.29 (d, 2H, C 6 H 5 ); 5.24 (s, 2H, NCH 2 ); 4.21 (s, 3H, OCH 3 ); 2.27 (s, 3H, CH 3 ); 2.17 (s, 3H, CH 3 ).
EXAMPLE 10
[0164] 1-Benzyloxy-3-benzyl-4,5-dimethylimidazolium bromide (4): Benzyl bromide (1.2 mL, ca. 10 mmol) was added via syringe to a refluxing suspension of 1 (1.0 g, 5.0 mmol) in dry benzene. A dark orange oil separated after refluxing for 6 h, and cooling to room temperature. The supernatant was decanted and the remaining oil was dried under vacuum overnight, which caused the product to solidify. The solid mass was crushed in pentane, filtered and dried under vacuum. Yield: 1.34 g (63%). 1 H-NMR (δ, CDCl 3 ): 11.04 (s, 1H, N—CH—N); 7.6-7.2 (ov. m, 10H, 2×C 6 H 5 ); 5.59, 5.58 (s+s, N—CH 2 , O—CH 2 ); 2.09, 1.94 (s, 3H, CH 3 , CH 3 ). 13 C-NMR (δ, CDCl 3 ): 132.8 (OCH 2 —C 6 H 5 ); 132.5 (NCN); 131.5 (NCH 2 - i C 6 H 5 ); 130.6, 130.3, 129.2, 129.0, 129.0, 128.9, 128.0 ( omp C 6 H 5 ); 124.8; 124.1 (NCCN); 83.9 (OCH 2 ); 51.2 (NCH 2 ); 8.89 (CH 3 ); 7.11 (CH 3 ).
EXAMPLE 11
[0165] 3-Benzyl-1-benzyloxy-4,5-dimethylimidazolium hexafluorophosphate (5): A batch of crude bromide 4 (still as an oil before drying under vacuum) was dissolved in DI water and extracted with hexanes. The aqueous layer was separated and a solution of ammonium hexafluorophosphate (ca. 1.3 equiv.) was added dropwise with constant stirring. The yellow oil deposited on the walls of the flask was dissolved in warm methanol and a few drops of hexanes were added. Cooling to room temperature afforded off-white crystals of pure 5, which were rinsed with pentane and dried under vacuum. Yield: (82% from 1). 1 H-NMR (δ, CDCl 3 ): 8.42 (s, 1H, N—CH—N); 7.45-7.35, 7.18 (ov. m, C 6 H 5 ); 5.31, 5.20 (s+s, N-CH 2 , O—CH 2 ); 2.13 (s, 3H, CH 3 ); 2.05 (s, 3H, CH 3 ).
[0166] Bis(1-Benzyloxy-3-benzyl-4,5-dimethylimidazolylidene)silver(I) dibromoargentate (6). The carbene precursor 6 was prepared as follows: A mixture of silver oxide (128 mg, 0.55 mmol) and imidazolium bromide 4 (396 mg, 1.06 mmol) was taken up in dry CH 2 Cl 2 and stirred at room temperature for 90 minutes. The dark orange suspension was filtered through a pad of celite and evaporated to dryness, yielding an orange powder. Crystallization from THF afforded a white powder (2 crops). Yield: 291 mg (57%). 1 H-NMR (δ, CD 2 Cl 2 ): 7.47-7.32 (ov. m, 10H, 2×CrH 5 ); 5.23, 5.22 (s+s, NCH 2 , OCH 2 ); 2.01, 1.95 (s, 3H+3H, CH 3 , CH 3 ). 13 C-NMR (δ, CD 2 Cl 2 ): 136.2 (NCN); 133.3 (OCH 2 — i C 6 H 5 ); 130.8 (NCH 2 — i C 6 H 5 ); 130.7, 130.0; 129.3, 129.3, 128.5, 127.1, 123.9 ( omp C 6 H 5 +NCCN); 82.6 (OCH 2 ); 54.0 (NCH 2 ); 9.4 (CH 3 ); 7.8 (CH 3 ). Anal. Found: C, 47.56; H, 4.26; N, 5.79%. Calc. for C 38 H 40 Ag 2 Br 2 N 4 O 2 : C, 47.53; H, 4.20;; N, 5.83%.
[0167] Examples 13 and 14 describe preparation of additional carbene precursors from N,N-diaryl-substituted diamines as illustrated in the schemes below.
[0168] Synthesis of carbene precursor 7 (2-pentafluorophenyl-1,3-diphenyl-imidazolidine): 200 mg (0.94 mmol, FW=212.12) N,N′-diphenyl-ethane-1,2-diamine was placed in a vial and dissolved in 5mL CH 2 Cl 2 . A catalytic amount of p-toluenesulfonic acid and 50 mg of Na 2 SO 4 were added, followed by 230 mg (0.94 mmol, FW=196.07) of pentafluorobenzaldehyde. The mixture was stirred for 8 h. The Na 2 SO4 was filtered off and solvent was removed under reduced pressure to yield a light brown powder 395 mg (FW=436.2), 96% yield. 1 H NMR: (400 MHz, CDCl 3 , 25° C.)=3.7-3.9 (m, 2H), 3.9-4.1 (m, 2H), 6.5 (s, 1H), 6.7-6.8 (m, 2H), 6.8-6.9 (m, 1H), 7.2-7.5 (m, 2H). 19 F NMR: δ=−143.2 (s br, 2F), −153.7-−153.8 (m, 1F), 161.7-−161.8 (m, 2F).
[0169] Synthesis of carbene precursor 8 (2-pentafluorophenyl-1,3-bis-(2,4,6-trimethyl-phenyl)-imidazolidine): Mesityldiamine (512 mg, 1.7 mmol) was placed into a vial, equipped with a stirbar, with pentafluorobenzaldehyde (340 mg, 1.7 mmol). Glacial acetic acid (5 mL) was added and the reaction was stirred at room temperature for 24 h. The acetic acid was removed under reduced pressure and the product was washed several times with cold methanol to afford the product as a white crystalline solid (543 mg, 65%). 1 H NMR: (400 MHz, CDCl 3 , 25° C.) δ: 2.2 (s, 12H), 2.3 (s, 6H), 3.5-3.6 (m, 2H), 3.9-3.4 (m, 2H), 6.4 (s, 1H), 6.9 (s, 4H). 19 F NMR: −136.3-−136.4 (m, 1F), −148.6-−148.7 (m, 1F), −155.8-−155.9 (m, 1F), −163.0-−163.3 (m, 2F). | A method is provided for carrying out depolymerization of a polymer containing electrophilic linkages in the presence of a catalyst and a nucleophilic reagent, wherein production of undesirable byproducts resulting from polymer degradation is minimized. The reaction can be carried out at a temperature of 80° C. or less, and generally involves the use of an organic, nonmetallic catalyst, thereby ensuring that the depolymerization product(s) are substantially free of metal contaminants. In an exemplary depolymerization method, the catalyst is a carbene compound such as an N-heterocyclic carbene, or is a precursor to a carbene compound. The method provides an important alternative to current recycling techniques such as those used in the degradation of polyesters, polyamides, and the like. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. Ser. No. 11/476,604, filed Jun. 29, 2006, which claims priority from Japanese Patent Application No. 2005-190130, filed on Jun. 29, 2005, the entire subject matters of which are incorporated herein by reference.
TECHNICAL FIELD
Aspects of the present invention relate to an image forming apparatus forming an image on a recording medium and, particularly, to an image forming apparatus that forms an electrostatic latent image on the surface of an image carrier, sticks toner on the electrostatic latent image and transfers the toner onto a recording medium to form an image, and to a process cartridge and developing cartridge used in the image forming apparatus.
BACKGROUND
A conventional image forming apparatus includes an image carrier, such as a photosensitive drum, on the surface of which an electrostatic image is formed. The image forming apparatus further includes a developing roller developing the electrostatic latent image by sticking toner on the surface of the image carrier and forms an image by transferring the toner stuck on the surface of the image carrier by the developing roller onto a recording medium. In this type of image forming apparatus, the electrostatic latent image is developed by sticking toner on the surface of the image carrier bearing the electrostatic latent image using the developing roller. The image corresponding to the electrostatic latent image is formed on the recording medium by transferring the stuck toner onto the recording medium.
In this type of image forming apparatus, various processing devices including a charger that uniformly charges the image carrier before the electrostatic latent image is formed on the surface of the image carrier by exposing and a transfer roller that transfers toner stuck on the surface of the image carrier onto the recording medium are provided around the image carrier. Voltage acting between the processing device or the above-mentioned developing roller and the image carrier may be applied (e.g. see JP-A-11-327288).
In the image forming apparatus, the charger and the developing roller are accommodated in a cartridge and detachable from the image carrier. The components are replaceable according to each life span. JP-A-11-184195 discloses an image forming apparatus in which voltage is applied to a developing unit accommodating a developing roller through a charging unit accommodating a charger.
SUMMARY
However, in the conventional image forming apparatus, an electric current may flow into the processing device although the developing cartridge accommodating the developing roller is separated. For example, in the image forming apparatus disclosed in JP-A-11-184195, it is structurally possible that an electric current may flow into a transfer charger and a transfer belt when the developing cartridge (developing unit) is detached. When the developing cartridge is detached, in general, an electric current flowing into a processing device is stopped by control of software. However, when the electric current is not normally controlled, voltage may be applied between an image carrier and a processing device regardless of separation of the developing cartridge.
When the developing cartridge is separated, toner is not applied to the surface of the image carrier. In this situation, if voltage is applied between the image carrier and the processing device, the image carrier may be damaged due to the amount of charge excessively stored in the image carrier.
Aspects of the invention provide an image forming apparatus preventing damage to an image carrier by stopping an electric current flowing into a processing device when a developing cartridge is separated from the image carrier, and a process cartridge and developing cartridge used in the image forming apparatus.
According to an aspect of the present invention, there is provided an image forming apparatus including: an image carrier; a developing cartridge detachably mountable with respect to the image carrier; a processing device to which voltage acting between the image carrier and the processing device is applied; and a first electrode, wherein the developing cartridge further includes: a developing roller on which toner is capable of being held; and a second electrode capable of being electrically connected with the first electrode when the developing cartridge is mounted with respect to the image carrier, the processing device further includes: a third electrode capable of being electrically connected with the second electrode when the developing cartridge is mounted with respect to the image carrier, wherein the second electrode positions the developing cartridge in an axial direction of the developing roller.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-sectional view showing the inside configuration of a laser printer according to an aspect of the invention;
FIGS. 2A and 2B are a side view and a vertical cross-sectional view, respectively, of a developing cartridge and photosensitive cartridge of the laser printer;
FIGS. 3A and 3B are a side view and a rear view of the developing cartridge, respectively; and
FIG. 4 is a partial top view of the photosensitive cartridge.
DETAILED DESCRIPTION
An aspect of the invention will be described hereinafter with reference to the accompanying drawings. FIG. 1 is a vertical cross-sectional view showing the inside configuration of a laser printer 1 . As shown in FIG. 1 , a sheet feed cassette 3 is mounted in a lower portion of a casing 2 . The casing 2 covers the main body of the laser printer 1 from the outer circumference. The sheet feed cassette 3 can be drawn out in a front direction of the laser printer 1 (i.e. the front when the laser printer 1 is set; the left side in FIG. 1 ).
A supporting plate 5 pushed up by a spring 6 is provided inside the sheet feed cassette 3 . A sheet feed roller 9 is disposed above a front end of the supporting plate 5 . The sheet feed roller 9 separates a pile of sheets P as recording media disposed on the supporting plate 5 and sends it one-by-one to an image forming portion 7 . A guide 11 that reverses a sheet P conveyed by the sheet feed roller 9 , conveying rollers 12 and 12 that subsequently convey the sheet P, and a pair of registration rollers 14 and 15 that stop a leading end of the sheet P and corrects the skew of the sheet P are sequentially disposed on a conveying path of the sheet P from the sheet feed roller 9 to the image forming portion 7 .
The image forming portion 7 includes a photosensitive drum 21 that serves as an image carrier and disposed inside a photosensitive cartridge 20 that serves as an image carrier cartridge. The image forming portion 7 further includes a transfer roller 22 that serves as a processing device and transfer unit. The transfer roller 22 is disposed to oppose the photosensitive drum 21 . The photosensitive drum 21 is a well-known drum formed by applying an organic photo conductor (OPC) on the surface of a grounded metal body.
A sheet P with an image formed by toner (described below) by passing between the photosensitive drum 21 and transfer roller 22 is sent to a fixing portion 31 . The toner image formed on the sheet P is nipped between a heating roller 33 and a pressing roller 35 and fixed by heat at the fixing portion 31 . The sheet P with the fixed image is then conveyed by a pair of conveying rollers 36 and 36 .
The sheet P conveyed by the conveying rollers 36 is guided to an upper portion of the casing 2 by a guide 37 and then discharged though a pair of sheet discharge rollers 38 and 38 onto a sheet discharge tray 39 provided on the top of the casing 2 . A scanner unit 90 , which exposes the photosensitive drum 21 to laser light L, is disposed between the sheet discharge tray 39 and the photosensitive cartridge 20 . The scanner unit 90 forms an electrostatic latent image by exposing the surface of the photosensitive drum 21 to the laser light L. The scanner unit 90 includes a laser light source, a polygon mirror, an fθ lens, and a reflecting mirror, etc (all not shown).
The configuration of the image forming portion 7 will be described hereafter in detail. The photosensitive cartridge 20 has the rotatable photosensitive drum 21 , the transfer roller 22 and a scorotron charger 23 that uniformly charges the surfaces of the photosensitive drum 21 . By the laser light L irradiated by the scanner unit 90 , an electrostatic latent image is formed on the surface of the photosensitive drum 21 charged by the scorotron charger 23 . A developing roller 41 (a developing unit), which is provided in a developing cartridge 40 (to be described below), applies toner onto the surface of the photosensitive drum 21 and the electrostatic latent image is subsequently developed. The toner stuck to the photosensitive drum 21 is transferred onto a sheet P passing between the photosensitive drum 21 and the transfer roller 22 . Thus, the image is formed on the sheet P through the above-described operations.
The developing roller 41 is rotatably supported in the developing cartridge 40 and rotates while contacting with the photosensitive drum 21 . The developing cartridge 40 also includes a toner accommodating portion 42 accommodating toner, an agitator 43 agitating the toner in the toner accommodating portion 42 , a feed roller 44 applying toner discharged from the toner accommodating portion 42 by the agitator 43 to the developing roller 41 , a developing blade 45 frictionally charging the toner stuck on the surface of the developing roller 41 and forming a thin layer of the toner, etc.
FIG. 2A is a side view of the developing cartridge 40 and FIG. 2B is a vertical cross-sectional view of the photosensitive cartridge 20 . As shown in FIG. 2B , the developing cartridge 40 and photosensitive cartridge 20 that compose a process cartridge indicated by a solid line are detachable from the laser printer 1 . The developing cartridge 40 is detachably mounted in the photosensitive cartridge 20 by fitting a rotational shaft 41 a of the developing roller 41 into guide grooves 20 a formed at both sides of the photosensitive cartridge 20 .
The developing cartridge 40 is provided with an electrode 51 having one end 51 a protruding downward from the developing roller 41 in a direction perpendicular to the rotational shaft 41 a and the other end 51 b protruding from the right side (this side in a direction perpendicular to the sheet of FIGS. 1 , 2 A and 2 B) of the toner accommodating portion 42 in the direction of the rotational shaft 41 a . When the process cartridge is mounted in the main body of the laser printer 1 , the end 51 b of the electrode 51 contacts with a leaf spring-shaped electrode 53 provided in the main body of the laser printer 1 , as shown in FIG. 3A . As shown in a side view and rear view of FIGS. 3A and 3B , the end 51 a of the electrode 51 is formed in a plate shape that is perpendicular to the rotational shaft 41 a of the developing roller 41 .
The lower surface of the developing cartridge 40 functions as a guiding surface that guides a sheet P between the photosensitive drum 21 and the transfer roller 22 . A plurality of ribs 40 a for guiding is provided along the conveying direction of the sheet P. As shown in FIG. 3B , the largest width Wa for sticking toner on the photosensitive drum 21 using the developing roller 41 and the largest sheet width Wb that is available to the laser printer 1 are shown for reference. As shown in FIG. 3B , the end 51 a of the electrode 51 is disposed outside the largest available sheet width Wb and protrudes downward from the guiding surface.
FIG. 4 is a partial view of a part of the photosensitive cartridge 20 lower than the photosensitive drum 21 . As shown in FIG. 4 , the upper surface of the photosensitive cartridge 20 is also used as a guiding surface guiding a sheet P between the photosensitive drum 21 and the transfer roller 22 and has guiding ribs 20 b that face the above-mentioned ribs 40 a . An end 61 a of an electrode 61 is disposed to face the end 51 a of the electrode 51 . The end 61 a branches into two parts to interpose the end 51 a of the electrode 51 between them and they hold the end 51 a tight in an axial direction of the rotational shaft 41 a using resin elasticity. On the other hand, the other end 61 b of the electrode 61 is in contact with a metallic rotational shaft 22 a of the transfer roller 22 . The end 61 b is formed into a leaf spring, and in contact with the rotational shaft 22 a , by pressing the end of the rotational shaft 22 a in the axial direction.
Accordingly, when the developing cartridge 40 is mounted in the photosensitive cartridge 20 as shown in FIG. 2B , the end 51 a of the electrode 51 is interposed between the two parts of the end 61 a of the electrode 61 and they are electrically connected. Since the end 51 a of the electrode 51 is interposed between the two parts of the end 61 a of the electrode 61 , the developing cartridge 40 is positioned in the axial direction of the developing roller 41 with respect to the photosensitive cartridge 20 .
When the photosensitive cartridge 20 and the developing cartridge 40 that are combined into a unit (a process cartridge) are mounted in the main body of the laser printer 1 , the end 5 lb of the electrode 51 is brought into contact with the electrode 53 and bias voltage is applied from the main body to the transfer roller 22 through the path of the electrode 53 →the electrode 51 →the electrode 61 →the rotational shaft 22 a . The bias voltage is constant-current-controlled by a control circuit (not shown). As described above, toner stuck on the photosensitive drum 21 is transferred onto a sheet passing between the photosensitive drum 21 and the transfer roller 22 by electrostatic attractive force. As the developing cartridge 40 is positioned, the photosensitive drum 21 and developing roller 41 are appropriately positioned with respect to each other. As a result, the electrostatic latent image formed on the photosensitive drum 21 is developed by toner excellently.
When the developing cartridge 40 is separated from the photosensitive cartridge 20 , the electrodes 51 and 61 are electrically disconnected. Accordingly, when only the photosensitive cartridge 20 is mounted in the main body of the laser printer 1 , bias voltage is not applied to the transfer roller 22 . Therefore, bias voltage is prevented from being applied to the transfer roller 22 when the developing cartridge 40 is not mounted in the printer, thus effectively preventing damage to the photosensitive drum 21 .
The both ends 51 a and 61 a are disposed outside the sheet conveying path formed by the guiding surfaces where ribs 40 a and 20 b are formed. Accordingly, when the ribs 20 b and 40 a are not normally positioned and a sheet P is not guided between the photosensitive drum 21 and transfer roller 22 , the ends 51 a and 61 a are disconnected, and bias voltage is not applied to the transfer roller 22 . Therefore, bias voltage is prevented from being applied to the transfer roller 22 when a sheet P cannot be guided between the photosensitive drum 21 and transfer roller 22 . As a result, damage to the photosensitive drum 21 is surely prevented.
Although the aspect of the present invention has been described in connection with the detailed aspects of the present invention, it will be apparent that various modifications and changes may be made thereto without departing from the scope and spirit of the invention. For example, the image carrier may not be formed in a drum shape, but may be a belt shape of a photosensitive belt, and may be detachably provided in the main body of the laser printer 1 . The transfer unit may not be limited to the roller, but may be a transfer belt or a transfer charger. The processing device may not be limited to the transfer unit, but may be other processing devices such as a conventional charging device that uniformly charges the surface of the photosensitive drum, or a conventional cleaning device that removes the toner or dusts from the surface of the photosensitive drum.
As was described, according to the above configuration, when the developing cartridge is mounted with respect to the image carrier, the electrodes provided at the processing device and the developing cartridge, respectively, are connected with each other and an electric current flows into the processing device. Accordingly, voltage is applied between the processing device and image carrier and an image is formed on a recording medium.
Further, when the developing cartridge is mounted with respect to the image carrier, the developing cartridge is positioned in the axial direction of the developing roller by connection of the pair of electrodes. Therefore, an image is excellently formed on a recording medium. Because the above-mentioned axial arrangement does not require severe precision, the electrodes are enough for the arrangement and other control members may not be required.
When the image carrier is separated from the developing cartridge, electric current cannot flow into the processing device in view of the structure because the electrodes are separated. Accordingly, when toner cannot be applied onto the image cartridge due to the separation of the developing cartridge, voltage is not applied between the image carrier and processing device. Therefore, it is possible to prevent damage to the image carrier.
Although the configuration of the electrodes is not limited, the developing cartridge may be configured so as to be detachable in a direction perpendicular to the axial direction of the developing roller and may be positioned by pinching one electrode of the developing cartridge or processing device by the other electrode in the axial direction.
A variety of processing device are considered, but the processing device may be a transfer unit to which bias voltage acting between the image carrier and the transfer unit is applied and that transfers the toner stuck on the surface of the image carrier onto the recording medium. In general, a transfer unit is constant-current-controlled for maintaining predetermined charged amount of a recording medium. In this configuration, when the developing cartridge is separated and the transfer unit is constant-current-controlled, excessive voltage may be applied to the image carrier. However, when the processing device is the transfer unit, voltage is not excessively applied to the image carrier. Accordingly, damage to the image carrier is effectively prevented. | An image forming apparatus that includes: an image carrier; a developing cartridge detachably mountable with respect to the image carrier; a processing device to which voltage acting between the image carrier and the processing device is applied; and a first electrode, wherein the developing cartridge further includes: a developing roller on which toner is capable of being held; and a second electrode capable of being electrically connected with the first electrode when the developing cartridge is mounted with respect to the image carrier, the processing device further includes: a third electrode capable of being electrically connected with the second electrode when the developing cartridge is mounted with respect to the image carrier, wherein the second electrode positions the developing cartridge in an axial direction of the developing roller. | 6 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method of manufacturing an alpha-sialon phosphor and, more particularly, to a method of stabilizing alpha-sialon phosphor raw powder that prevents the deterioration of photoluminescence intensity according to humidity or the like in the raw powder treatment process.
2. Description of the Related Art
There are various methods of emitting white light from an LED system. For this purpose, typically, an LED system includes a blue LED chip and a yellow phosphor excited by the chip. Various types of LED systems have been developed since a YAG-Ce based yellow phosphor excited by a blue LED chip made of a GaN thin film was developed.
Such a yellow phosphor is a material indispensable for emitting white light because it is a material for converting near-ultraviolet light or blue light emitted from an LED chip into visible light observed with the naked eye. Currently, high-grade sensitive illuminators that can control color rendering properties and color temperature are being intensively developed by increasing the illumination efficiency of an illuminator and appropriately mixing green, yellow and red phosphors, for the purpose of the advance of white LEDs into general illumination markets. Currently, among these phosphors, an oxynitride-based phosphor, which is formed by replacing all or part of oxygen atoms of an industrially-used oxide-based phosphor with nitrogen atoms, is being intensively researched all over the world, because it exhibits excellent excitation/luminescence characteristics and high stability to temperature/humidity due to its strong covalent bonds and low electron affinity.
Meanwhile, a conventional alpha-sialon phosphor is generally synthesized by sintering a Si 3 N 4 —CaO—AlN—Eu 2 O 3 based raw powder mixture at high temperature. However, this method is problematic in that a large amount of oxide is used, so the content of oxygen becomes high, and thus it is difficult to increase photoluminescence intensity and convert emission peak wavelengths into long wavelengths.
In order to solve the above problem, Japanese Unexamined Patent Application Publication No. 2005-307012 discloses a Ca—Eu-α-sialon, whose Ca solid solution range is wide compared to conventional α-sialon due to the use of nitride as a Ca 2+ source (stabilization ion) instead of oxide, and which can easily disperse Eu 2+ having a large ion radius in a solid solution.
PRIOR ART DOCUMENTS
Patent Documents
Japanese Unexamined Patent Application Publication No. 2005-307012
Japanese Unexamined Patent Application Publication No. 2005-235934
Japanese Unexamined Patent Application Publication No. 2006-124501
Japanese Unexamined Patent Application Publication No. 2010-47772
Japanese Unexamined Patent Application Publication No. 2012-512307
SUMMARY OF THE INVENTION
The present inventors found that an alpha-phase stabilizing compound such as Ca 3 N 2 is very unstable when exposed to air and does not exhibit desired photoluminescence intensity in certain working environments. Based on these findings, the present invention was devised.
Accordingly, an object of the present invention is to provide a pretreatment process for stabilizing calcium nitride (Ca 3 N 2 ) contained in raw powder for preparing an alpha-sialon phosphor.
Another object of the present invention is to provide a method of manufacturing an alpha-sialon phosphor whose photoluminescence intensity is not deteriorated due to working environments, and to a composition for manufacturing the alpha-sialon phosphor.
In order to accomplish the above objects, an aspect of the present invention provides a method of manufacturing alpha-sialon phosphor, including the steps of: mixing raw powder including Si 2 N 4 , AlN, a rare-earth metal oxide and calcium nitride (Ca 3 N 2 ) as a calcium source; heat-treating the raw powder to convert the calcium source into Ca—Al—Si—N based compound comprising CaAlSiN 3 or CaAl 2 Si 4 N 8 ; and sintering the heat-treated raw powder thereby forming alpha-sialon phosphor.
In the method, the step of converting the calcium source into a Ca—Al—Si—N based compound may be performed at a temperature of 1000° C. or more under a nitrogen atmosphere.
Preferably, the step of converting the calcium source into the Ca—Al—Si—N based compound may be performed at a temperature of 1000˜1250° C., and preferably at 1100˜1200° C., under a nitrogen atmosphere.
Further, in the method, a mixing apparatus for performing the step of mixing the alpha-sialon phosphor raw powder and a heat treatment apparatus for the step of converting the calcium source into the Ca—Al—Si—N based compound may communicate with each other under a nitrogen atmosphere.
Another aspect of the present invention provides a method of manufacturing an alpha-sialon phosphor, including the steps of: mixing raw powder including Si 3 N 4 , AlN, a rare-earth metal oxide and CaAlSiN 3 or CaAl 2 S 4 N 8 as a calcium source; and sintering the raw powder thereby forming alpha-sialon phosphors.
Still another aspect of the present invention provides an alpha-sialon phosphor composition, including Si 3 N 4 , AlN, a rare-earth metal oxide and a Ca—Al—Si—N based compound and represented by Ca x Si 12-m-n Al m+n O n N 16-n :Re y (here, Re is an activator and is at least one selected from the group consisting of Eu, Ce, Tb, Yb, Sm and Dy, 1.5≦m≦3.5, 0.02≦y≦0.15, m=2x+3y, 0.03<n<1.0).
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a graph showing the weight gain of alpha-sialon raw powder with respect to exposure time when the alpha-sialon raw powder mixed in a glove box was exposed to moisture in a temperature-humidity-controlled bath having a temperature of 25° C. and a relative humidity of 90% according to Example of the present invention;
FIG. 2( a ) shows the results of measuring the photoluminescence intensity of the phosphor powder synthesized by sintering the alpha-sialon raw powder exposed to moisture in the temperature-humidity-controlled bath at high temperature in a gas-pressure sintering furnace at an excitation wavelength of 390 nm, while FIG. 2( b ) shows photoluminescence intensity at an excitation wavelength of 450 nm;
FIG. 3 is a graph showing the results of TG-DTA analysis of alpha-sialon phosphor raw powder;
FIG. 4 is a graph showing the results of XRD analysis of alpha-sialon phosphor raw powder having passed through heat treatment;
FIG. 5 is a graph showing the results of XRD analysis of alpha-sialon phosphor raw powder having passed through gas-pressure sintering;
FIG. 6 is a graph showing the results of measuring the weight change of alpha-sialon phosphor raw powder in response to humidity conditions;
FIG. 7 is a graph showing the results of analysis of the oxygen content of alpha-sialon phosphor powder synthesized by stabilization heat treatment and moisture exposure;
FIG. 8 is a graph showing the results of XRD analysis of alpha-sialon phosphor powder synthesized by gas-pressure sintering; and
FIG. 9 is a graph showing the results of analysis of photoluminescence characteristics of alpha-sialon phosphor powder synthesized under a stabilization heat treatment condition and a moisture exposure condition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiment of the present invention will be described in detail with reference to the attached drawings.
The Composition Formula of a stabilized alpha-sialon (α-sialon) phosphor is represented by the following Formula 1:
M x Si 12−m−n Al m+n O n N 16−n :Re y <Formula 1>
(here, Re is an activator and is at least one selected from the group consisting of Eu, Ce, Tb, Yb, Sm and Dy, 1.5≦m≦3.5, 0.02≦y≦0.15, m=2x+3y, 0.03<n<1.0).
Here, the added Li, Mg, Ca and/or Y act as an alpha-phase stabilizer.
Therefore, the Composition Formula of the Ca-stabilized alpha-sialon phosphor is represented by the following Formula 2:
Ca x Si 12−m−n Al m+n O n N 16−n :Re y . <Formula 2>
Meanwhile, the alpha-sialon phosphor represented by the above Formula 2 may be prepared by using Si 3 N 4 , AlN and Ca 3 N 2 as starting materials. In a case where a very small amount of surface oxides (SiO 2 , Al 2 O 3 ) are included in the starting material powder (Si 3 N 4 and AlN), the alpha-sialon phosphor may be represented by the following Formula 3:
a Si 3 N 4 +b SiO 2 +c AlN+ d Al 2 O 3 +e Ca 3 N 2 +f Eu 2 O 3 =g Ca x Si 12−(m+n) Al (m+n) O n N 16−n :Eu y . <Formula 3>
For example, Table 1 below shows the combination ratio of the alpha-sialon phosphor represented by Formula 3 in which m=3, y=0.05, and n=0.52. Here, it is assumed that Si 3 N 4 powder contains 1.25 wt % of SiO 2 , and AlN powder contains 1.5 wt % of Al 2 O 3 .
TABLE 1
Si 3 N 4 (g)
AlN (g)
Ca 3 N 2 (g)
Eu 2 O 3 (g)
Eu (at %)
63.96
23.32
11.30
1.41
0.17
In the process of stabilizing the alpha-sialon phosphor raw powder of the present invention, Ca 3 N 2 included the raw powder is converted into a Ca—Al—Si—N based compound which is a stabilizing compound. Examples of the Ca—Al—Si—N based compound may include CaAlSiN 3 , CaAl 2 Si 4 N 8 and the like. For example, the formation reaction of CaAlSiN 3 is represented by the following Formula 4:
Ca 3 N 2 +3AlN+Si 3 N 4 =3CaAlSiN 3 . <Formula 4>
Further, the present invention provides a method of synthesizing an alpha-sialon phosphor using CaAlSiN 3 as a calcium (Ca) source instead of Ca 3 N 2 . In this case, the synthesis of an alpha-sialon phosphor is represented by the following Formula 5:
a Si 3 N 4 +b SiO 2 +c AlN+ d Al 2 O 3 +e CaAlSiN+ f Eu 2 O 3 =g Ca x Si 12−(m+n) Al (m+n) O n N 16−n :Eu y . <Formula 5>
For example, Table 2 below shows the combination ratio of the alpha-sialon phosphor represented by Formula 5 in which m=3, y=0.05, and n=0.52.
TABLE 2
Si 3 N 4 (g)
AlN (g)
CaAlSiN 3 (g)
Eu 2 O 3 (g)
Eu (at %)
53.03
13.18
31.38
1.41
0.17
The present invention provides a method of stabilizing an alpha-sialon phosphor using Ca 3 N 2 as a calcium (Ca) source. Further, the present invention provides a method of manufacturing an alpha-sialon phosphor using a Ca—Al—Si—N based compound (stabilizing compound) as a calcium (Ca) source. Hereinafter, these methods will be described in more detail with reference to the following Examples.
TEST EXAMPLE
Raw powder was combined in a glove box under a nitrogen atmosphere according to the combination ratio of raw powder shown in Table 1 above. Starting powder was weighed according to Table 1, and was then dry-mixed using a household food mixer provided with a teflon-coated blade.
The raw powder mixed in the glove box was exposed to moisture in a temperature-humidity-controlled bath having a temperature of 25° C. and a relative humidity of 90%, and then the weight change thereof was measured.
FIG. 1 shows the weight gain of raw powder with respect to exposure time when the raw powder mixed in a glove box was exposed to moisture in a temperature-humidity-controlled bath having a temperature of 25° C. and a relative humidity of 90%. In FIG. 1 , a large graph shows the weight change rate of raw powder, and a small graph in the large graph shows the reaction degree of raw powder with respect to exposure time when the final change degree of raw powder was set 100 after exposing the raw powder to moisture for 2 hours.
From FIG. 1 , it can be seen that raw powder containing Ca 3 N 2 reacts with external moisture very rapidly. Further, in terms of degree of reaction thereof, it can be seen that 20% or more of the entire reaction thereof was conducted within 1 minute, 60% of the entire reaction thereof was conducted after 5 minutes, 80% or more of the entire reaction thereof was conducted after 10 minutes, and 97% or more of the entire reaction thereof was conducted after 10 minutes, at which point the reaction was nearly completed.
When raw powder was exposed to moisture for 2 hours, the weight gain of the raw powder was about 6.9%, which is greater than the theoretical weight gain (5.64%) thereof when Ca 3 N 2 is completely converted into Ca(OH) 2 . The reason for this is that moisture is adsorbed on the surface of raw powder under a high-humidity condition.
As mentioned above, a predetermined amount of the raw powder discharged from the temperature-humidity-controlled bath was charged in a BN container in the glove box by its own gravity due to free fall. The charged raw powder was synthesized into a phosphor at high temperature in a gas pressure sintering (GPS) furnace pressurized by nitrogen. The synthesis condition thereof is that the raw powder was heated from room temperature to 900° C. under a vacuum atmosphere, was pressurized to 0.5 MPa by charging nitrogen gas (N 2 ) at 900° C., and then the pressure was maintained at the final synthesis temperature. The final synthesis temperature was 1800° C., and the pressure was maintained for 4 hours at the final synthesis temperature. The synthesized phosphor was formed into phosphor powder by alumina-induced pulverization. Subsequently, the formed phosphor powder was analyzed.
FIG. 2 shows the results of measuring the photoluminescence (PL) intensity of the phosphor powder synthesized by sintering the raw powder exposed to moisture in the temperature-humidity-controlled bath at high temperature in the gas pressure sintering (GPS) furnace. The measurement of the photoluminescence (PL) intensity of the phosphor powder was performed using an excitation 200 W Xe lamp (manufactured by PSI Corporation), and wavelengths of 390 nm and 450 nm were used as excitation wavelengths. In the graphs of FIG. 2 , the photoluminescence (PL) intensity thereof was normalized based on a commonly-used alpha-sialon phosphor (manufactured by Denka Co., Ltd.).
From FIG. 2 , it can be seen that a difference in the photoluminescence (PL) intensity of the phosphor powder barely occurs when exposure time is less than 1 minute. However, it can be seen that, when exposure time is 5 minutes or more, the PL intensity thereof rapidly decreases at an excitation wavelength of 390 nm, and the PL intensity thereof somewhat decreases even at an excitation wavelength of 450 nm. Further, it can be seen that, when exposure time exceeds 10 minutes, the PL intensity thereof at an excitation wavelength of 390 nm is decreased by about 20% compared to when the phosphor powder was not exposed to moisture, and the PL intensity thereof was continuously maintained thereafter. Further, it can be seen that the PL intensity thereof at an excitation wavelength of 450 nm is somewhat increased with the passage of exposure time, but is decreased compared to the initial PL intensity thereof as shown in the graphs of FIG. 2 .
It is known that the PL intensity of an alpha-sialon phosphor decreases when the content of oxygen in the alpha-sialon phosphor increases. Further, it is known that, when the content of oxygen in the alpha-sialon phosphor increases, a dominant wavelength (DWL) is shifted to a short wavelength band, and the shift is caused by the deterioration of an electron cloud effect and covalent properties due to the decrease in the content of nitrogen in the alpha-sialon phosphor. Accordingly, from the results of FIG. 2 , it is presumed that, when raw powder containing Ca 3 N 2 is exposed to moisture, the amount of oxygen in the synthesized phosphor powder increases, thus remarkably deteriorating the luminescence characteristics of the phosphor powder. Therefore, it is required that calcium nitride used as a calcium source for manufacturing an alpha-sialon phosphor must be stabilized.
The TG-DTA analysis of raw powder was conducted according to the combination ratio of Table 1. FIG. 3 is graph showing the results of TG-DTA analysis of raw powder. In this case, the TG-DTA analysis of raw powder was conducted under the condition that raw powder is not exposed to moisture or air. Further, the TG-DTA analysis of raw powder was conducted at a temperature range of 40˜1600° C., and was performed under a nitrogen atmosphere.
From the results of the TG-DTA analysis of raw powder, it is presumed that the weight of raw powder was not greatly changed. However, as shown in the heat flow graph of FIG. 3 , it can be ascertained that a strong endothermic reaction takes place at a temperature range of 830° C. to 1200° C.
Considering the melting points of various nitrides and oxides added to raw powder (Si 3 N 4 : 1900° C., AlN: 2200° C., Ca 3 N 2 : 1195° C., Eu 2 O 3 : 2350° C.), it is inferred that the endothermic reaction is caused by a chemical reaction rather than by melting. Further, it can be inferred that the lowest point of the endothermic reaction is 1000° C., and the endothermic reaction is finished at 1200° C. Therefore, the heat treatment temperature range suitable for stabilizing Ca 3 N 2 may be 1000˜1250° C., and preferably 1100˜1200° C.
EXAMPLE
The raw powder mixed according to the combination ratio of Table 1 above was heat-treated under a nitrogen atmosphere. The heat treatment of the raw powder was performed in a tube furnace connected to a glove box.
The heat treatment of raw powder was carried out under the conditions of 1000° C. 4 hours, 1200° C. 4 hours and 1200° C. 24 hours at a heating rate of 10° C./min. After the heat treatment thereof was finished, the heat-treated raw powder was cooled to room temperature, and was then transferred to the glove box without being exposed to the outside.
FIG. 4 is a graph showing the results of XRD analysis of the heat-treated raw powder. In FIG. 4 , samples are indicated by T10t4, T12t4 and T12t24, respectively, according to heat treatment temperature and time, and the raw powder, which was not heat-treated, is indicated by noHT.
Referring to FIG. 4 , it can be ascertained that, in the case of noHT, which was not heat-treated, a small amount of Ca(OH) 2 was detected. It is inferred that this result be caused by the inevitable exposure of noHT to air during the storage or XRD analysis thereof, although noHT was not intentionally exposed to moisture.
Further, it can be ascertained that, in the case of T10t4, neither a Ca 3 N 2 peak nor a Ca(OH) 2 peak was detected, and that, in the case of T12t4 and T12t24, a CaAlSiN 3 peak was detected. Here, it is inferred that the CaAlSiN 3 peak was shifted at a high angle compared to the peak on the typical JCPDS card.
It is inferred that, in the case of T10t4, the temperature is low enough to cause a CaAlSiN 3 reaction, and an amorphous reaction intermediate can be formed in this sample. Further, it is inferred that, in the case of T10t4, alpha-sialon was not synthesized at this temperature, based on the fact that the Si 3 N 4 peak of this sample is identical to the peak on the typical JCPDS card and a small amount of AlN remains in this sample.
Meanwhile, the results of measuring the PL intensity of T12t4 and T12t24 show that a luminescence peak was detected at an excitation wavelength of 450 to 640 nm. This luminescence peak is identical to the red luminescence spectrum of CaAlSiN 3 . From this result, it can be ascertained that, in these samples, CaAlSiN 3 was produced at relatively low temperature.
Each of the heat-treated samples was synthesized into an alpha-sialon phosphor in a gas pressure sintering (GPS) furnace. At the time of synthesis of the alpha-sialon phosphor, the sample was heated from room temperature to 900° C. under a vacuum atmosphere, was pressurized to 0.5 MPa by charging nitrogen gas (N 2 ) at 900° C., and then the pressure was maintained at the final synthesis temperature. The final synthesis temperature was 1800° C., and the pressure was maintained for 4 hours at the final synthesis temperature. The synthesized alpha-sialon phosphor was formed into alpha-sialon phosphor powder by alumina-induced pulverization. Subsequently, the formed alpha-sialon phosphor powder was analyzed.
FIG. 5 is a graph showing the results of XRD analysis of the gas pressure-sintered samples. In FIG. 5 , the sample, which was synthesized into an alpha-sialon phosphor without performing the heat treatment for stabilization, is indicated by noHT.
Referring to FIG. 5 , it can be ascertained that all the samples were synthesized into alpha-sialon phosphors. Further, it can be ascertained that, in the heat-treated sample, CaAlSiN 3 , which is an intermediate product formed during heat treatment, was not detected. The reason for this is that CaAlSiN 3 was converted into alpha-sialon during a high temperature synthesis process, and was thus eliminated.
In parts of the samples, a small amount of an unidentified agent was detected. It is inferred that the unidentified agent is a vitric by-product containing Si, Al, O and N. As a result of computing the m value of samples from XRD peak data, it was ascertained that all the samples have an m value of about 2.4, which is lower than the target value (m=3). It can be inferred that the reason for this is that the amount of Ca and Eu in crystal becomes lower than the target value thereof because the surface of raw powder is liquefied during a high-temperature reaction.
Further, from the fact that a final product of the sample having passed through heat treatment for stabilization and a final product of the sample (noHT) not having passed through heat treatment for stabilization show similar phase analysis results to each other, it can be ascertained that a stable alpha-sialon phosphor can be finally produced by the process of stabilizing raw powder using heat treatment.
Hereinafter, the analysis results related to the resistivity of raw powder having passed through heat treatment for stabilization to humidity will be described.
FIG. 6 is a graph showing the results of measuring the weight changes of raw powder stabilized by heat treatment and raw powder that has not been heat-treated, in response to various humidity conditions. In the graph in FIG. 6 , RH45 means a relative humidity of 45%, and RH90 means a relative humidity of 90%. Here, exposure time was set to 2 hours.
From FIG. 6 , it can be seen that the degree of the weight gain of each of the samples (noHT and T10t4) is great, regardless of humidity conditions, and that the weight gain of each of the samples (T12t4 and T12t24) is less than 1%. It is inferred that about 1% of the weight gain of each of the samples (T12t4 and T12t24) is related to moisture adsorption. Consequently, it can be ascertained that CaAlSiN 3 , produced by stabilizing T12t4 and T12t24 using heat treatment, is a material that has very high resistance to moisture exposure.
However, it was observed that the weight gain of each of the samples (T12t4 and T12t24) was greater under the condition of RH90 than under the condition of RH45. For this reason, it can be inferred that it is difficult to control the quality of an alpha-sialon phosphor in response to humidity change when samples are not stabilized by heat treatment. However, since the reaction of T10t4 with moisture under the condition of RH45 is slow compared to the reaction of noHT with moisture under the condition of RH45, it can be inferred that the heat treatment for stabilization assures resistance to moisture to some degree, although the sample is not completely stabilized by the formation of CaAlSiN 3 .
FIG. 7 is a graph showing the results of analysis of the oxygen content of final alpha-sialon phosphor powder synthesized by stabilization heat treatment and moisture exposure. The analysis of the oxygen content thereof was conducted using an oxygen/nitrogen analyzer (TC-436, manufactured by LECO Corporation in U.S.A).
The oxygen contents of alpha-sialon phosphors (noHum-GPS, RH45-GPS, RH90-GPS) synthesized according to the stabilization conditions (noHT, T10t4, T12t4, T12t24) and the moisture exposure conditions (noHum, RH45, RH90) were indicated, and, for comparison, oxygen contents of raw powder before the synthesis of alpha-sialon phosphors according to the moisture exposure conditions (noHum, RH45, RH90) were also indicated. Here, in the case of sample noHum under the condition of noHT, the theoretical oxygen content thereof was indicated, and this theoretical oxygen content was calculated in consideration of the oxygen content of an oxide film formed on the surface of raw powder (Si 3 N 4 powder and AlN powder).
In the case of samples (noHum, RH45, RH90) that had not passed through an alpha-sialon phosphor synthesis process using GPS, it was observed that, at the time of moisture exposure, the oxygen contents thereof were increased similarly to the weight gains thereof shown in FIG. 6 . That is, in the case of noHT and T10t4, the oxygen contents thereof were greatly increased, and in the case of T12t4 and T12t24, the oxygen contents thereof were slightly increased.
Meanwhile, in the case of samples (noHum, RH45, RH90) that had passed through an alpha-sialon phosphor synthesis process using GPS, it was observed that the oxygen contents thereof were greatly decreased. It can be inferred that the reason for this is that Ca(OH) 2 is decomposed into CaO and H 2 O during heat treatment, and Si 3 N 4 (average particle size: 0.2 μm) is formed into alpha-sialon of a size of several micrometers, so crystallization and grain growth of alpha-sialon takes place, thereby decreasing the oxygen contents thereof.
Nevertheless, in the case of samples (noHT, T10t4) contaminated by moisture exposure, each of the samples has a high oxygen content of 4˜5 wt %, which is two times that of the theoretical oxygen content thereof, even after GPS synthesis. However, in the case of samples (T12t4, T12t24) stabilized by heat treatment, each of the samples has a high oxygen content which is similar to the theoretical oxygen content thereof.
The XRD analysis of raw powders exposed to moisture under the condition of RH45 was conducted after GPS synthesis. FIG. 8 is a graph showing the results of XRD analysis thereof in the region of 2θ=26˜35°.
Referring to FIG. 8 , it can be seen that the alpha-sialon peaks of phosphor powders (noHT, T10t4) are shifted to the right, with the result that the m values of these phosphor powders are lower than those of other samples.
In the alpha-sialon phosphor represented by Ca x Si 12−m−n Al m+n O n N 16−n :Re y , wherein m=2x+3y, when m decreases, the amount of Ca and Eu solid-dispersed in alpha-sialon decreases. This means that Ca and Eu are not solid-dispersed in the lattice of alpha-sialon, and remain in an amorphous liquid phase. Further, when the content of oxygen in phosphor powder increases, the liquid phase is excessively created, and particles strongly agglomerate, so a large amount of energy is required to perform a pulverizing process. Therefore, when the content of oxygen in phosphor powder increases, an electron cloud effect is deteriorated due to a decrease in the amount of nitrogen, and photoluminescence characteristics are deteriorated due to a reduction of covalent properties. Further, when the content of oxygen in phosphor powder increases, the degree of solid dispersion of Ca and Eu is decreased due to the excessive formation of a liquid phase, and photoluminescence characteristics are deteriorated due to the defects occurring during pulverization.
FIG. 9 is a graph showing the results of analysis of photoluminescence characteristics of alpha-sialon phosphor powder synthesized under a stabilization heat treatment condition and a moisture exposure condition. Here, an excitation wavelength was set at 390 nm.
Referring to FIG. 9 , it can be seen that the PL intensity of the sample stabilized by heat treatment at 1200° C. under the moisture exposure condition of noHum is decreased by about 1˜3%. However, the PL intensity of each of the samples (noHT and T10t4) under the moisture exposure condition of RH45 and RH90 is decreased by 20% or more, but the PL intensity of each of the samples (T12t4 and T12t24) is similar to that of the sample under the moisture exposure condition of noHum.
As described above, the present invention provides a technology of stabilizing alpha-silalon phosphor raw powder containing a calcium nitride source to have high photoluminescence intensity. According to this technology, a reliable alpha-sialon phosphor having high photoluminescence intensity can be manufactured regardless of weather, season, environment and the like.
Further, the present invention provides an alpha-sialon phosphor raw powder composition containing a Ca—Al—Si—N based compound as a calcium source and a method of manufacturing an alpha-sialon phosphor using the composition. In the present invention, since the Ca—Al—Si—N based compound is solid-dissolved in the lattices of alpha-sialon phosphor raw powder to be consumed, this alpha-sialon phosphor is very suitably used as a monochromatic phosphor for realizing a white LED in combination with a blue light emitting device.
Although the preferred 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 herein is a method of stabilizing alpha-sialon phosphor, including the steps of: mixing raw powder including Si 3 N 4 , AlN, a rare-earth metal oxide and calcium nitride (Ca 3 N 2 ) as a calcium source; heat-treating the raw powder to convert the calcium source into Ca—Al—Si—N based compound comprising CaAlSiN 3 or CaAl 2 Si 4 N 8 ; and sintering the heat-treated raw powder thereby forming alpha-sialon phosphor. This method is advantageous in that a reliable alpha-sialon phosphor having high photoluminescence intensity can be manufactured regardless of weather, season, environment and the like. | 2 |
FIELD OF THE INVENTION
[0001] The present invention is in the field of patch-pumps having a primary-container, said primary-container storing the drug to be delivered. In particular, the present invention addresses the creation of a fluid connection between said primary-container and a cannula assembly associated with said patch-pump. In some aspects, the present invention is particularly suitable for prefilled patch-pump application.
BACKGROUND TO THE INVENTION
[0002] Infusion pumps are used for treating a number of disease states requiring subcutaneous delivery of a drug. As part of the current trend towards enhanced usability, some infusion pumps are now being produced as “patch-pumps”, meaning that the long tube between a remote pump and the infusion-set on the skin is eliminated. Instead, a device with a similar footprint to the infusion-set alone constitutes the entire pump, including the drug-reservoir and the actuator which drives the drug infusion. However, even though this transition to patch-pumps represents a miniaturization of the product, typically the filling process by which the patient fills the drug reservoir remains the same and is performed at the point-of-use. Other approaches for providing the drug in a patch-pump are (a) inserting a cartridge containing the drug into the patch-pump, and (b) having a pre-filled drug reservoir integrally contained within the patch-pump already during the pump manufacturing process; said drug-reservoir thereby constituting the primary-container for the drug. Whereas the act of inserting a cartridge-type reservoir into the patch-pump can open a liquid channel from the cartridge to the cannula assembly, for a drug-reservoir that is assembled within the patch-pump, an alternative means of creating this fluid connection is required.
OBJECTS OF THE INVENTION
[0003] Thus the objective of the present invention is to enable a fluid connection to be created between an integral, optionally pre-filled drug-reservoir within a patch-pump and the cannula insertion assembly associated with said patch-pump.
[0004] It is a further object of the invention to ensure that the pre-filled drug-reservoir remains sealed or that a sterile unit containing such drug reservoir be maintained as such, until directly before the activation of the patch-pump, such that the only materials that come in contact with the drug are the plastic and/or glass from which the reservoir is fabricated and one or more septa.
[0005] It is a still further object of the invention to open said fluid connection while keeping the operation of said patch-pump as simple as possible and requiring a small number of activation-steps.
SUMMARY OF THE INVENTION
[0006] The core element therefore of the present invention is a mechanism and method for exploiting one of the activation-steps required to initiate the operation of a patch-pump to create a fluid connection between the pre-filled drug reservoir assembly of said patch-pump and the cannula assembly associated with said patch-pump.
[0007] The cannula assembly of a patch-pump may be associated with the patch-pump in a number of different ways: (a) fully integrated, in which case said cannula assembly is integrated within the housing of the patch-pump, as per the OmniPod product from Insulet Inc. (MA, USA); (b) external, in which case a short tube extends from the patch-pump to a small infusion set directly adjacent to (or sharing an adhesive pad with) the patch-pump; or (c) attached to, and preferably also detachable from, the housing of the patch-pump as per the preferred embodiment detailed below.
[0008] The present invention describes the automatic opening of a liquid channel between a sealed pre-filled drug-reservoir and said cannula assembly as a result of one of the activation-steps undertaken when starting the patch-pump. Such steps typically include placing the patch-pump on the skin of the patient, removing a safety catch, or pressing a button which causes the cannula to be inserted or activates the actuator of said patch-pump. According to the present invention, the performance or one or more of these activation-steps will cause the automatic opening of a fluid channel between the pre-filled reservoir and the cannula assembly without a dedicated step being required for this purpose. Advantageously, this simplifies the use of the patch-pump while simultaneously ensuring that the pump cannot be activated in a state in which it is only later determined that the pre-filled reservoir remains sealed.
[0009] In one embodiment, said opening of the fluid channel is performed automatically either on the step of removing a safety catch or cover, or a step of activating the cannula insertion.
[0010] In some embodiments, this invention provides a selectively activatable patch-pump assembly, said patch-pump assembly comprising:
a sealed prefilled drug-reservoir containing a drug to be delivered; an associated conduit in connection therewith; a selectively activatable penetrator which penetrates said sealed prefilled drug-reservoir and facilitates drug access to said conduit; and a selectively activatable associated cannula-containing assembly for delivering a drug subcutaneously to a subject, in fluid connection with said conduit;
wherein a selective activation-step initiates penetration of said sealed prefilled drug-reservoir, drug access from said drug-reservoir to said conduit, drug access from said conduit to said cannula-containing assembly and delivery from said cannula-containing assembly, thereby being a selectively activatable patch-pump assembly.
[0015] According to this aspect, and as referred to herein the term “selectively activatable” is to be understood to refer to a requirement for an activation step, i.e., a specific action to be taken to produce the outcome. For example, and representing some embodiments, the term “selectively activatable patch-pump assembly” is to be understood to encompass an assembly whose delivery of the drug via known patch-pump mechanisms, is regulated such that an activation step is required or delivery from the patch pump is prevented.
[0016] Similarly, the term “selectively activatable penetrator”, relates to a penetrator mechanism which penetrates a prefilled drug-reservoir and does so in a selective manner, thereby preventing spontaneous rupture of such reservoir.
[0017] Similarly, the term “selectively activatable associated cannula-containing assembly”, relates to an assembly which provides for delivery of a drug subcutaneously to a subject, and does so in a selective manner, thereby preventing spontaneous subcutaneous puncture of the subject.
[0018] It is to be understood that the invention provides a number of devices, which uniquely regulate coordinated activation steps for the selective penetration of a drug reservoir releasing such drug-containing contents into a proximal conduit, which conduit is selectively put into contact with an access port in a cannula-containing assembly, regulating delivery of such drug-containing contents subcutaneously to said subject.
[0019] In some embodiments, the selectively activatable penetrator comprises a hypodermic needle. In other embodiments, the selectively activatable penetrator comprises any appropriate structure capable of penetrating the drug reservoir in a controllable manner.
[0020] The sealed prefilled drug-reservoir containing a drug to be delivered is located proximally, and is associated with a conduit in connection therewith. It will be appreciated that the conduit may be of any suitable material, size and geometry to suit a particular device.
[0021] The conduit, in turn, may contain, or at least partially include therewithin a selectively activatable penetrator which penetrates said sealed prefilled drug-reservoir and facilitates drug access to said conduit. In some embodiments, such conduit may contain a septum, which prevents access of the outside environment to said drug reservoir, thereby maintaining a sterile environment for said drug reservoir.
[0022] In some embodiments, the selectively activatable penetrator is located within the conduit and is located minimally or partially within the septum, providing easier access to such drug reservoir upon activation thereof.
[0023] The selectively activatable associated cannula-containing assembly is located in fluid connection with the conduit.
[0024] According to this aspect, and in some embodiments, the cannula-containing assembly provides for the delivery of the drug-containing substance liberated from the drug reservoir. In some embodiments, such cannula-containing assembly comprises a part capable of piercing the skin. In some embodiments, such cannula-containing assembly may resemble a venicath or similar structure, which provides for skin puncture to promote subcutaneous delivery. In some embodiments, such catheter-containing part may be flexible or rigid.
[0025] A selective activation-step initiates penetration of said sealed prefilled drug-reservoir, drug access from said drug-reservoir to said conduit, drug access from said conduit to said cannula-containing assembly and delivery from the cannula-containing assembly.
[0026] In some embodiments, the selectively activatable patch-pump assembly mechanism further comprises a safety catch or cover preventing the inadvertent activation of the patch-pump.
[0027] According to this aspect, and in some embodiments, such safety catch may comprise a pin, or slot, or other structure, which locks or otherwise prevents the penetrating member from penetrating the drug reservoir, and or prevents the cannula-containing assembly from advancing within said patch pump assembly and initiating subcutaneous delivery.
[0028] In some embodiments, removal or release of a safety catch or a cover, or a combination thereof, comprises the activation-step which initiates penetration of the sealed prefilled drug-reservoir and facilitates drug access to the conduit.
[0029] In some embodiments, the selectively activatable patch-pump assembly further comprises a first spring-based mechanism, which propels the selectively activatable penetrator through the conduit and in some embodiments, through the septum, toward the sealed prefilled drug-reservoir, thereby facilitating penetration of the drug-reservoir.
[0030] In some embodiments, the selectively activatable patch-pump assembly further comprises a second spring-based mechanism, which propels the cannula-containing assembly toward proximally located skin following drug access to the conduit.
[0031] In some embodiments, the cannula-containing assembly comprises an access port, which access port is alignable with the conduit in a selective manner. In some embodiments, only activation, for example by depressing a button on a top or side of such device, results in controlled propelling of the cannula-containing assembly toward the skin of a wearer thereof, whereby an access port in such cannula-containing assembly is only aligned with the conduit when propelled sufficiently toward the skin of the subject.
[0032] In some embodiments, the selectively activatable patch-pump assembly further comprises an actuator which compresses said prefilled drug-reservoir following penetration of said sealed prefilled drug-reservoir.
[0033] Such actuator and arrangement may comprise any known means, and in some embodiments, specifically contemplates a drug delivery actuator such as that described in United States Patent Application Publication Number US 2009-0093772, fully incorporated by reference herein and United States Patent Application Publication Number US 2010-0022992, fully incorporated by reference herein.
[0034] In some embodiments, the selectively activatable patch-pump assembly is a single unit.
[0035] In some embodiments, the selectively activatable patch-pump assembly is comprised of operationally connectable units comprised of a drug reservoir-containing unit and a cannula-containing assembly.
[0036] From a user-convenience perspective, the less number of activation-steps used the better. However, in order to minimize the chance of inadvertent activation, it is wise to also have a safety catch or cover. Thus, in the present invention, it is immaterial whether the activation-step which opens up the fluid channel between the prefilled-reservoir and the cannula assembly is the safety catch step or the cannula-insertion one.
[0037] In a further embodiment, the cannula insertion also activates the actuator of the patch-pump, such that the number of activation-steps is reduced to the lowest practical minimum, thereby enhancing simplicity while improving patient compliance.
[0038] In another embodiment of the approach in which removing the safety catch (or safety cover) opens said fluid channel, removal of said catch releases a spring-loaded hollow penetrating-member to penetrate through a septum of said drug-reservoir, said penetrating-member then serving as a fluid conduit towards the cannula assembly. In this way, the drug-reservoir remains sealed until just before use.
[0039] In another embodiment, the conduit leads to a passageway which interfaces with the cannula assembly, such that when the cannula is inserted into the skin said passageway is then placed in fluid connection with said cannula.
[0040] According to this aspect, the fluid connection from the prefilled drug-reservoir to the cannula is completed. Note that said cannula assembly may employ either a soft-cannula or a rigid-cannula.
[0041] Some embodied contemplated devices are explained more fully below, in connection with the figures, but the same shall not be construed as limiting the invention.
[0042] All publications, patents, and patent applications mentioned herein are hereby incorporated by reference in their entirety as if each individual publication or patent was specifically and individually indicated to be incorporated by reference. In case of a conflict between the specification and an incorporated reference, the specification shall control. Where number ranges are given in this document, endpoints are included within the range. Furthermore, it is to be understood that unless otherwise indicated or otherwise evident from the context and understanding of one of ordinary skill in the art, values that are expressed as ranges can assume any specific value or sub-range within the stated ranges, optionally including or excluding either or both endpoints, in different embodiments of the invention, to the tenth of the unit of the lower limit of the range, unless the context clearly dictates otherwise. Where a percentage is recited in reference to a value that intrinsically has units that are whole numbers, any resulting fraction may be rounded to the nearest whole number.
FIGURES
[0043] FIGS. 1 a and 1 b provide exploded and assembled isometric views of an embodied patch-pump incorporating the present invention, respectively;
[0044] FIG. 2 provides an isometric cut-away view of the assembled patch-pump showing the prefilled-reservoir and the cannula assembly;
[0045] FIGS. 3 a and 3 b show cross-sectional views of the patch-pump before and after removal of the safety cover;
[0046] FIGS. 4 a , 4 b and 4 c provide planar cut-away views showing the stages of the opening of the fluid channel as said safety cover is removed.
[0047] FIGS. 5 a and 5 b show an embodied orientation and construction/arrangement of a fluid conduit system connecting the drug reservoir-containing element and cannula containing element.
[0048] FIGS. 6 a , 6 b , 6 c , 6 d , 6 e and 6 f provide cut-away isometric views of an embodied patch-pump showing the stages of engagement of the elements for penetration of the drug-containing reservoir, activation of the cannula-containing assembly, and potential regulation of the same.
[0049] FIGS. 7 a , 7 b , 7 c and 7 d depict an embodied patch pump of this invention in various cutaway views, to highlight certain elements of the device, and provide for ease of view of the same.
[0050] FIG. 8 provides an embodied assembly comprised of operationally connectable units comprised of a drug reservoir-containing unit and a cannula-containing assembly, as opposed to the single unit, depicted in FIGS. 1-6 .
DETAILED DESCRIPTION OF THE INVENTION
[0051] One embodiment of a patch-pump containing a mechanism of the present invention is shown in exploded form in FIG. 1 a , in which a cannula assembly 10 , associated with the patch-pump 12 , is attached to the housing of the patch-pump as per option c) above. Additionally, in this patch-pump, a safety cover 14 is employed to cover said cannula assembly 10 , preventing the inadvertent insertion of the cannula before it is required.
[0052] FIG. 1 b then shows said patch-pump in its assembled form, it being understood that said safety cover 14 is grasped and removed by the patient immediately prior to activation of the pump.
[0053] As will be detailed in connection with the following figures, in this preferred embodiment, removal of this cover 14 initiates the creation of a fluid connection from the drug-reservoir to the cannula.
[0054] Referring now to FIG. 2 , this cut-away view shows certain component parts of the patch-pump mechanism and how they interact in order to enable the mechanism of the present invention to function in this described embodiment.
[0055] According to this aspect, and in one embodiment, a drug is contained within a sealed prefilled drug-reservoir 20 , which is formed in the volume between a rigid reservoir wall 22 and a flexible reservoir wall 24 . The pump may further comprise an actuator 26 , which expands and by doing so moves the flexible wall 24 towards the rigid wall 22 ; thereby compressing the drug-reservoir 20 in order to expel the drug. The drug reservoir 20 further comprises a septum 28 at the end of a conduit 29 leading from the drug reservoir 20 , said septum 28 sealing said reservoir while allowing penetration thereof using a hollow penetrating member.
[0056] Referring now to FIG. 3 a , this figure shows how, in this preferred embodiment, the safety cover 14 comprises an internal pin 30 which serves to restrain a first spring 32 in its compressed state. FIG. 3 a then shows how the removal of said safety cover 14 enables said spring 32 to expand until it hits a stop 34 .
[0057] Referring now to FIG. 4 a , a planar view showing the spring 32 in its compressed state is shown, and then FIG. 4 b shows how the release of said spring 32 causes a penetrating-member 40 to pierce said septum 28 , emerging in said conduit 29 , thereby effecting a fluid connection between the interior of the drug-reservoir 20 and the fluid-passageway 42 leading to the cannula 44 .
[0058] FIG. 5A shows an enlarged side perspective view of the device. The septum 28 and its piercing by the penetrating member 40 are seen in this view. FIG. 5B shows an exploded view of an embodiment of a fluid connection between the interior of the drug reservoir as it enters the fluid passageway 42 and its conveyance to the cannula 44 .
[0059] Referring now to FIGS. 6 a through 6 f, the details of how the drug from the fluid-passageway 42 flows through to the interior of the cannula 44 as the cannula is inserted into the body, are shown. In this embodiment, the type of cannula used permits an insertion-needle, which in turn, leads the cannula into its place and can be withdrawn. The steps of this process serve to create the above mentioned fluid connection, as follows.
[0060] FIG. 6 a - 6 b shows the overall arrangement of the cannula insertion mechanism and its fluid connection to the drug reservoir, including an enlargement of the fluid connection, as shown in the inserts in FIG. 6 a and FIG. 6 b . In this aspect, the piercing of the septum 28 by the first penetrating member 40 , permits fluid exit from the drug reservoir 20 into the fluid passageway 42 .
[0061] FIG. 6 c shows the initial state of the cannula insertion mechanism in which both the insertion-needle 50 and cannula 44 are within the patch-pump. In this initial state, the flow from the passageway 42 is blocked by a plastic sleeve 52 , ensuring that none of the drug is lost until the cannula 44 has been inserted under the skin. Referring now to FIG. 5 b , the state in which the needle-insertion spring 56 has pressed the cannula-connector 54 down to the point where it comes in contact with the sleeve 52 . Note that at this point the tips of the needle 50 and cannula 44 start to emerge from the base of the patch-pump. Referring now to FIG. 5 c , the state in which the needle-insertion spring 56 has come to the end of its travel is shown. In this state, cannula-connector 54 has now moved down the sleeve 52 and taken its place. Also visible in this view is the hole 58 in the cannula-connector 54 which is now situated opposite the passageway 42 . The final stage in the cannula insertion is now shown in FIG. 5 d , in which the cannula-connector 54 has had the needle removed, leaving just the cannula 44 in place. In this state, the hole 58 in the cannula-connector 54 is aligned with the passageway 42 and thus enables flow of the drug from said passageway 42 through to the end of the cannula 44 ; thereby completing the liquid connection from the pre-filled drug-reservoir all the way to the subcutaneous layer.
[0062] FIG. 7 depicts an embodied patch pump of this invention in various cutaway views, to highlight certain elements of the device, and provide for ease of view of the same. FIG. 7 a provides a side, cut-away view of the device, showing various elements of the drug insertion mechanism and drug reservoir element and connection between the same, prior to activation of the device. FIG. 7 c shows and side and partial top cut away view of the device in FIG. 7 a , emphasizing placement of the cannula 44 traversing the device in order to promote penetration of the skin proximally located beneath the device. The relative positioning of the drug reservoir 20 , septum 28 and first spring 32 are shown, as well. The conduit 42 in fluid connection with both the drug reservoir and cannula containing assembly is seen, as well. FIGS. 7 b and 7 d provide line and filled in drawings of the connection between the drug reservoir and cannula containing assembly.
[0063] FIG. 8 shows another embodied device of the invention. According to this aspect, the drug reservoir and associated elements 60 are attachable to the drug insertion mechanism 62 , in a manner facilitating fluid communication, as in the embodied device in FIGS. 2-6 . In this aspect, multiple drug-containing reservoir elements 60 can be attached to the drug insertion means 62 .
[0064] It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as set forth in the appended claims. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed in the scope of the claims.
[0065] In the claims articles such as “a,”, “an” and “the” mean one or more than one unless indicated to the contrary or otherwise evident from the context. Claims or descriptions that include “or” or “and/or” between members of a group are considered satisfied if one, more than one, or all of the group members are present in, employed in, or otherwise relevant to a given product or process unless indicated to the contrary or otherwise evident from the context. The invention includes embodiments in which exactly one member of the group is present in, employed in, or otherwise relevant to a given product or process. The invention also includes embodiments in which more than one, or all of the group members are present in, employed in, or otherwise relevant to a given product or process. Furthermore, it is to be understood that the invention provides, in various embodiments, all variations, combinations, and permutations in which one or more limitations, elements, clauses, descriptive terms, etc., from one or more of the listed claims is introduced into another claim dependent on the same base claim unless otherwise indicated or unless it would be evident to one of ordinary skill in the art that a contradiction or inconsistency would arise. Where elements are presented as lists, e.g. in Markush group format or the like, it is to be understood that each subgroup of the elements is also disclosed, and any element(s) can be removed from the group. It should be understood that, in general, where the invention, or aspects of the invention, is/are referred to as comprising particular elements, features, etc., certain embodiments of the invention or aspects of the invention consist, or consist essentially of, such elements, features, etc. For purposes of simplicity those embodiments have not in every case been specifically set forth in haec verba herein. Certain claims are presented in dependent form for the sake of convenience, but Applicant reserves the right to rewrite any dependent claim in independent format to include the elements or limitations of the independent claim and any other claim(s) on which such claim depends, and such rewritten claim is to be considered equivalent in all respects to the dependent claim in whatever form it is in (either amended or unamended) prior to being rewritten in independent format. | The present invention provides a selectively activatable patch-pump assembly, said patch-pump assembly comprising: •a sealed prefilled drug-reservoir containing a drug to be delivered; •an associated conduit in connection therewith; •a selectively activatable penetrator which penetrates said sealed prefilled drug-reservoir and facilitates drug access to said conduit; and •a selectively activatable, associated, cannula-containing assembly for delivering a drug subcutaneously to a subject, in fluid connection with said conduit; wherein a selective activation-step initiates penetration of said sealed prefilled drug-reservoir, drug access from said drug-reservoir to said conduit, drug access from said conduit to said cannula-containing assembly and delivery from said cannula-containing assembly, thereby being a selectively activatable patch-pump assembly. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is in the field of machines for producing braided structures useful inter alia as reinforcements for composites.
2. Description of the Related Art
The braiding process is one of the traditional methods of interconnecting strands of fibers into fabrics, ropes and tubes.
In the braiding process, yarns are normally fed through a machine where they are caused to interlace with each other to form various braided structures. Such structures, following their early use in the reinforcement of hoses such as fire hoses, have become increasingly important in the reinforcement of so-called composite structures of various shapes and uses.
The usual braiding machine interlaces yarns as follows. Braiding yarns, wound on bobbins, are carried on a carrier which is said to `float` with respect to the rest of the machine because they are not permanently attached to the rest of the machine. Typically a plurality of carriers move in intersecting paths in the braiding plane, generally half in each direction. The result is that the `free` ends of the yarns are interlaced over and under other yarns at the braid formation point The carriers are generally propelled in guiding slots by means of notched disks called `horn gears`. Rotating close together in opposite directions, the gears pass the carriers from one gear to another. Such a system is shown, for example, in U.S. Pat. No. 3,981,223.
The carriers usually move in a roughly horizontal plane, usually called the braiding plane. The point at which the braid is assembled, called the braiding point, lies above the plane.
However, it is not necessary to the functioning of the braider that the braiding plane be horizontal and that the braiding point be above the plane. U.S. Pat. No. 4,304,169 shows a braiding machine wherein a series of alternate braiding planes and braiding points are arranged in a horizontal configuration. The invention of this application can be applied to any single or series arrangement regardless of the orientation of the device.
The term `yarn` as used herein is intended to comprise all forms of yarn, synthetic or natural, organic or metallic of any cross section.
Naturally, as in most active arts, many variations are known and practiced. For example, it is common practice to enclose so-called axial yarns in braided structures. Axial yarns are yarns which are simply fed into the braided structure without themselves being interlaced about other yarns; they are held in place by yarns which are interlaced as described above.
Since the bobbins move with respect to the braiding point, means are usually needed to maintain approximately constant tension in the yarn leaving the bobbin and to take up yarn when the bobbin moves in the direction of the braiding point. This is variously accomplished, e.g. by providing a spring loaded idler wheel to each yarn combined with a pawl to prevent excessive unwinding from the bobbin.
Common to most commercial braiders is a high degree of mechanical complexity and specialization such that a particular machine is often capable of producing only a single braiding design without extensive modification.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a simple braiding machine capable of easy conversion from one task to another.
More specifically this invention is directed to a braiding machine comprising one or more bobbin carriers moving along a braiding path in the braiding plane, wherein the improvement comprises bobbin carriers which are self-propelled; and the further improvement that said braiding path or track consists of interchangeable units comprising guidance slots and means for delivering electric power to the self-propelled carriers, said units providing cross-overs and curves to the track.
A still further improvement is provided in a yarn tensioner comprising:
(a) A bracket having an essentially straight slot comprising a first end and a second end, said slot surrounding a first axle, said first axle being free to move in said slot in an essentially straight line essentially at right angles to the principal axis of said first axle;
(b) a spring urging said axle toward said first end;
(c) a yarn bobbin and a first pulley mounted coaxially on said first axle;
(d) a drive belt engaging said first pulley and a second pulley lying on an essentially straight line extension from the second end of said slot;
(e) said second pulley being in mechanical communication with a motor normally turning in a direction to roll up yarn on said bobbin;
(f) means for directing yarn onto said bobbin from the direction of the second end of said slot whereby tension in said yarn urges said first axle in a direction opposed to the urging of said spring whereby to reduce tension in and cause slippage in said drive belt.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, isometric drawing showing a single bobbin embodiment of the invention. FIG. 2 shows a crossover track unit of the invention, hereinafter called a tile. FIG. 3 is a side view of FIG. 2. FIG. 4 shows a 90 degree curve tile of the invention. FIG. 5 shows a 180 degree tile of the invention. FIG. 6 is a schematic drawing showing the course of a simple braiding path about axial yarn guides. FIG. 7 shows a more complex track produced by the same three kinds of tiles. Invention devices having the braiding path arrangement of FIGS. 6 and 7 produce two-step braids as described, for example, in U.S. Pat. No. 4,719,837. The path of FIG. 7 produces a T-beam composite structure reinforcement. FIGS. 8 and 9 show a simple tensioner capable of maintaining constant tension and of taking up slack yarn.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is further elaborated in the description following the term "self-propelled" as applied to bobbin carriers is intended to mean that energy such as electrical energy initiates mechanical movement in the carrier itself, as opposed to the case in art devices wherein energy, alreadY in the form of mechanical energy is transferred to the bobbin carrier, for example, by a horn gear.
Turning now to FIG. 1, one sees a schematic, isometric drawing of a single bobbin embodiment of the invention. Entering the braiding plane 1 are axial yarns 2 originating at a source outside the invention device. Axial yarns 2 pass over a roller 3 after which they are distributed to short pipe-like guides 4 which guide the axial yarns for a sufficient distance above braiding plane 1 that bobbin carrier 5, comprising a braiding yarn bobbin and an electric drive motor, can follow path 6 without interference. Braiding yarn 7, shown as a broken line, as a result of the course taken by carrier 5, interlaces with axial yarns at braiding point 8. Pins at stop point 30, controlled by the controller shown, engage, when raised, a micro switch 31 on bobbin carrier 5 thus stopping the carrier. These arrangements are not strictly necessary in the single bobbin carrier embodiment of this figure. They are necessary in multi-bobbin carrier embodiments because carriers do not always complete their rounds at the same time. For this reason, all carriers are stopped by these means after completing their rounds to give the slower carriers time to catch up.
FIG. 2 shows crossover 20 comprising track 21, the track in this embodiment consisting of slot 22 and electrical conductor strips 23. Dowel pin holes 24 provide for dowels 27 to hold the tiles together. Cut-out sections 25 provide space for guides 4. Wires 26 provide electrical connection to electrical conductor strips 23. Electricity supply is provided from underneath by connections not shown.
FIG. 3 shows a view from one side of FIG. 2.
FIG. 4 shows a 90 deg curve tile 20A and FIG. 5 shows a 180 deg curve tile 20B. It is preferred, although not necessary, to employ a single 180 deg tile as opposed to using two 90 deg tiles. The component numbers correspond to those of FIG. 2.
FIG. 6 shows the course of a simple track 6 passing between guides 4. Stop points 30 are controller- or timer-actuated pins which rise to engage micro switches 31 (see FIG. 8) on carriers 5 so as to cause them to pause until all cars have completed their rounds, normally two cycles. The track of FIG. 6 is capable of operation with a single carrier, although a plurality can be employed.
FIG. 7 shows a more complex track requiring at least two carriers. This drawing shows the manner in which tiles of the invention are assembled. For simplicity, stop points are not shown. Representatives of each of the three preferred kinds of tiles are set out with stippling add identified. The track produces a two-step braided T-beam reinforcement.
FIG. 8 shows a yarn bobbin and tensioner assembly carried in carrier 5. The assembly is capable not only of providing constant tension but also of taking up slack yarn when, for example, the vector distance between the travelling bobbin and the braiding point decreases, e.g., when the carrier moves toward the center of the braiding plane. As is seen in the figure, bobbin 40 carrying yarn and supported on axle 41, comprises an integral belt-engaging surface 42. Axle 41 and bobbin 40 are urged upward in slot 43 by spring 44 which is in tension and adjustable by means not shown. The upward urge exerted bY spring 44 is opposed by belt 45, forces exerted by the braiding operation on yarn 7 (see FIG. 9), and, of course, the weight of the device. When the pull exerted on the yarn by the braiding operation increases, the downward pull on the bobbin causes decreased tension on belt 45 thus allowing the belt to slip somewhat thus reducing thereby the tendency of motor 46 to resist the pull-off of yarn from bobbin 40. When, however, the tension is reduced, e.g. the yarn becomes slack, the bobbin rises and tension on belt 40 is increased, thereby transferring turning force to bobbin 40 and rolling up slack yarn.
Component 47 is a flange which confines yarn to bobbin 40. Metal bracket 49 contains slot 43. T-shaped member 50 prevents carrier 5 from leaving track 23. Wheels 52 are connected to drive motor 46 by means of belted wheel 56.
FIG. 9 shows a partially cut away end view of the tensioner assembly.
The materials of construction are a matter of choice for the skilled artisan. It is convenient to employ poly(methylmethacrylate) for the construction of the tiles, although other materials such as aluminum or steel can also be used, provided that insulation measures are taken, as will be evident to the artisan. Slots 22 are fabricated with an undercut to accomodate a T-shaped member 50 attached to carrier 5 to prevent carrier 5 from leaving the track. If it is expected that long runs will be undertaken, it is preferred to employ a T-shaped member comprising two wheels, preferably with roller or ball bearings, to engage the top surfaces of the undercut. The electrical conductor strips 23 are preferably fabricated from copper although other metals of good conductivity are operable. The conductors are attached to the tile by conventional means such as riveting or adhesion. The conductors bring electric power from a convenient source outside this invention, to the carrier 5 drive motor and optionally a second motor dedicated to regulating yarn tension, one or both being contained in carrier 5. It is preferred to employ a single drive motor and that this motor be employed both to drive the wheels of the carrier and to maintain yarn tension as shown in FIGS. 8 and 9 and in the above description. The electric current is carried from the electrical conductor strips to the carrier and motor(s) by means of a brushes 54. Other means may be employed, e.g., unshod wheels may be so arranged as to carry out this task. The drive wheels may be simple rubber-shod wheels which engage the flat surface of the tile, or cog wheels may be employed to engage cogs in the tile, not shown. | A simple braiding machine readily adaptable to a variety of braiding tasks comprises self-propelled bobbin carriers guided by a track consisting of interchangeable units similar to the interchangeable track units of a toy train. Also disclosed is a simple yarn tensioner capable of maintaining constant tension in the braiding yarn and capable of taking up slack yarn. | 3 |
BACKGROUND OF THE INVENTION
The general construction design for an alumina reduction cell cathode comprises an outer open-top steel shell, several layers of high, intermediate and low temperature insulation refractories on the bottom of the steel shell and, in some instances, on the sidewalls of the steel shell, a layer of prebaked and/or monolithic rammed carbon on the bottom and sidewalls of the cell, a monolithic, prebaked carbon cathode on the floor of the cell, and busbars extending from the carbon cathode through the sidewalls of the cell for connection to an electrical system supplying the current necessary for reduction of alumina contained in the cell to aluminum.
An alumina reduction cell requires adequate insulation on the bottom and sidewalls of the cathode to limit heat losses from the steel shell during cell operation. Cryolitic salts and vapors, containing an excess of sodium fluoride, penetrate through the carbon bottom and sidewalls during operation of the cell over its normal four to six year lifespan, and chemically attack and degrade the insulation. As the insulation is degraded, it loses its effectiveness as a thermal insulation material and heat losses through the insulation increase. As a consequence, the cell voltage must be increased to maintain a stable thermal equilibrium in the cell. If the cell voltage is not increased, the temperature of the cryolite-alumina electrolyte decreases, resulting in an increase in anode effect frequency from a normal average of one anode effect per day per cell to about two to three anode effects per day per cell.
An increased anode effect frequency significantly decreases the productivity of the potline to which the cell is connected. First, the productivity of the cell experiencing the anode effect is reduced due to increased bath temperature and increased turbulence within the cell occurring during the anode effect. Additionally, the line amperage of all the reduction cells in the potline is affected. Alumina cells in a potline are connected in an electrical series. When an anode effect occurs in one of the cells, the line amperage typically decreases between about 3000 to 5000 amps, due to the high voltage, approximately 20 to 50 volts, on the cell having the anode effect, as opposed to the typical 5 to 7 volts of a normal cell. Thus, the productivity of all cells in the potline decreases during each anode effect.
Thus, as is readily apparent, increased heat losses from cathodes, as a result of degradation of the insulation by cryolitic salts, results in an increase in energy consumption and/or decrease in productivity of the cells.
The highly corrosive cryolitic salts and vapors penetrating the cathode can be stopped in one of two ways. The temperature isotherm directly above the insulation material may be kept sufficently low, typically below about 600° C. to prevent any mobility of the salts below their freezing point. Alternatively, a vapor-proof barrier that will effectively resist the chemical attack of the cryolitic salts for the life of the cathode may be maintained in the cell.
In modern reduction cells, heat losses from the bottom and sides are reduced to conserve energy by adding additional layers of insulation and/or using insulation with lower thermal conductivities. This results in temperature isotherms directly above the insulation greater than about 800° C., due to the reduction of heat flow through the insulation. Because of this higher surface temperature, the insulation will be attacked and degraded faster by the cryolitic salt vapors as the temperature isotherm at the surface of the insulation exceeds the freezing point of the salts, typically in the range of 700° to 800° C. Thus, reliance upon vapor barriers is the only viable alternative in modern alumina reduction cells for insulation protection.
Various materials have been used in the past to protect alumina reduction cell insulation material. For example, mild steel is often placed over the insulation material forming the bottom of the cell. While steel barriers are somewhat effective, they are themselves attacked and eroded by the cryolithic material, usually within about two to three years, and sooner if the carbon cathode develops cracks.
There are other disadvantages to be noted when employing steel as a barrier material. Increased steel thickness will gain only slightly increased barrier life, but at a substantial increased cost. Thus, the cost-benefit ratio of steel is poor. It is also difficult and expensive and to purchase a large, one-piece sheet of steel sufficient to cover the entire bottom surface of the cathode. At the same time, welding several smaller pieces of steel together will cause the composite sheet to warp, causing voids in the insulation.
Substituting stainless steel for mild steel does increase the barrier properties, but at a cost prohibitively high and with significant increased difficulty of welding.
Another approach used for protecting the floor insulation of a cell is a mortared layer of fire brick or tile. These tiles or bricks are joined with a high temperature mortar. While used extensively abroad, such barriers have not gained acceptance in the United States, due to the exceptionally high cost in increased construction time resulting from the brick laying process, both in materials and labor. Further, even when installed, there is a weak link in this system, namely, the mortar. The mortar does not have the same physical and chemical resistance as the bricks to the cryolitic salts. As a result, cryolitic salts and vapors eventually penetrate through the mortar, around the bricks, and attack the insulation.
Recently, it has been proposed to employ a layer of glass sandwiched between alumina silicate fiber blankets to form a thin chemical barrier against cryolitic salts, due to the formation of higher melting point compounds, such as napthalenes, etc. Although this concept appeared feasible during a one-year experiment, it has not proven successful in barring cryolitic salts and vapors for the full four to six year lifetime of a cell. It has been found that the higher melting point compounds will be attacked, dissolved and degraded by the highly corrosive cryolitic salts and that the overwhelming supply of semi-molten cryolitic salts and vapors attacks and corrodes the relatively thin glass layer. For example, in a typical alumina reduction cell, the cathode weight often doubles during the four to six year life of cell operation due to the absorption of cryolitic salts into the cathode lining. The relatively thin glass layers have been unable to withstand this quantity of corrosive material.
There is a need, therefore, for a vapor barrier to protect the insulation layers on the bottom of an electrolytic alumina reduction cell. There is also a need for a vapor barrier which may be employed on the sidewalls of a alumina reduction cell having insulated sidewalls. It is thus the primary objective of the present invention to provide such vapor barriers.
THE PRESENT INVENTION
By means of the present invention, this goal is obtained. According to a first aspect of the present invention, a castable refractory layer is formed upon the insulation material on the floor of the cell.
Accordingly to a second aspect of the present invention, the insulation material on the sidewalls of the cell, and optionally, on the floor of the cell, are coated with a silicon carbide mortar. If the silicon carbide mortar is employed on the bottom of the cell, the castable refractory is formed thereon.
The castable refractory and mortar layers act as vapor barriers for the insulation material, thus increasing the useful life of the insulation material and decreasing the cost of operation of the cell over an extended period of time.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE in the drawing is a cross-sectional view of the cathode of an alumina reduction cell employing the protective barrier layers of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the FIGURE, an alumina reduction cell cathode 1 is shown in cross section. The cell 1 includes a generally rectangular shaped open top steel shell 10, several layers of high, intermediate and low temperature insulation refractories 26 on the bottom and within shell 10, a layer of insulation refractory 12 on the sidewall of the shell 10, a layer of prebaked and/or monolithic rammed carbon 16 on the bottom and sidewal1s of cell 1, a carbonaceous cathode 18 and busbars 20 which connect the cathode 18 to a source of electrical current.
The insulation block layers 12 and 26 are covered with vapor barrier layers 14 and 24 respectively. The vapor barrier layers 14 and 24 are formed from a silicon carbide mortar. The mortar is formed from a composition comprising from about 5 to about 10 percent by weight water and from about 90 to about 95 percent by weight of a mixture comprising about 75 to about 85 percent by weight silicon carbide and from 15 to about 25 percent by weight of a binder. The binder may be, for example, sodium aluminate, silicate or phosphate.
The vapor barrier layers 14 and 24 are formed from the composition as stated above and applied while still wet to the insulating block layers 12 and 26 and a thickness ranging from about 1/8 to about 1" in thickness, preferably about 1/4" thick.
The vapor barrier layers 14 and 24 provide several advantages. Silicon carbide mortar has been proven to be effective in resisting attack by molten cryolite when employed as a mortar between silicon carbide bricks in the sidewalls of alumina reduction cells and thus act in the same manner to resist molten cryolite as a mortar covering insulating blocks 12 and 26. Silicon carbide mortar forms a strong bond to steel and refractories at elevated temperatures, thus helping to ensure stability to the cell over its life span. Silicon carbide mortar forms a good air setting bond, and can be cured completely when the cell is baked or started. Silicon carbide mortar can be easily applied to refractory bricks or insulating slabs prior to their installation, but are preferably applied directly to the bricks or insulating slabs after they have been installed in place on the cathode. Silicon carbide mortar provides chemical protection for refractory bricks or insulating slabs in the sidewalls against both cryolite salts and vapors from the electrolyte, and from molten aluminum. This will prevent the molten aluminum from penetrating the carbon cathode through cracks and attacking the insulation and/or providing increased transport of cryolitic salts into the insulation.
On the bottom of cell 1, another vapor barrier is employed. A one-piece vapor barrier consisting of a castable refractory 22 covers the insulating blocks 26 on the floor of the cell. As illustrated in the FIGURE, castable refractory layer 22 is formed on mortar layer 24. However, this is not required. If mortar layer 24 were not employed, then layer 22 would be formed directly on insulation blocks 26. This would normally be the case, if insulating blocks 12, and thus mortar 14, were not employed, but may also be the case where blocks 12 and 14 are employed.
The castable refractory 22 comprises from about 75 to about 94.5 percent by weight of a refractory comprising from 5 to about 10 percent by weight water, from about 45 to about 55 percent by weight alumina and from about 40 to about 50 percent by weight silica, from about 0.5 to about 5.0 percent by weight fibers, and from about 5 to about 20 percent by weight filler. The fibers may be formed of such materials as stainless steel, silicon carbide, carbon, aluminum silicate and the like and may range from about 1 to about 2 centimeters in length. The filler may be formed from, for example, silica or silicon carbide particles having a particle diameter of from about 1 to about 15 microns. The castable refractory layer 22 may have a thickness, for example, of from about 2 to about 6 inches.
The castable refractory layer 22 provides several advantages to an alumina reduction cell. The one-piece monolithic castable refractory layer 22 eliminates seam weakness inherrent in brick or other similar barriers. The castable refractory 22 also provides chemical resistivity equal to that of fire brick or tiles. The utilization of fibres of appropriate length in the monolithic layer 22 provides crack arresters to inhibit cracking during baking, startup and operation of the cell, increasing the stability of layer 22 and thus the life of the cell, as well as reducing locations for migration of cryolitic salts to the insulation layers 26. The filler material reduces thermal expansion and increases density of the monolithic layer 22. The low linear shrinkage, which is typically less than about 0.5 percent, of the monolithic castable refractory layer reduces chances for cracking. The high bulk density and low porosity of castable refractory layer 22 reduces penetration and reaction by cryolitic salts and vapors.
The castable refractory layer 22 is formed by mixing the appropriate amount of water with the other component materials until the mix is uniformly wet and homogeneous and the mix is then poured into the cathode, spread and smoothed with a rotary blade cement finisher. The castable refractory is cured by holding the cell 1 at ambient temperature of between about 25° and 35° C. for 24 hours, slowly heating the cell 1 at rate of about 25° C. per hour until the layer 22 reaches about 110° C., holding the layer 22 at about 110° C. for about 24 hours, heating the cell 1 at a rate between about 50° and 75° C. per hour until the layer 22 reaches about 600° C. and holding the cell 1 at about 600° to 700° C. for 24 hours.
From the above, it is clear that the vapor barrier protection for an alumina reduction cell cathode provided by the present invention results in a cathode of increased life and/or increased productivity during its effective life.
While the invention has been described with reference to certain specific embodiments thereof, it is not intended to be so limited thereby, except as set forth in the accompanying claims. | An improved alumina reduction cell is disclosed. Vapor barriers, formed from a castable refractory and a silicon carbide mortar protect the bottom and sidewall insulation material of the cell from attack by the corrosive materials contained within the cell. | 2 |
FIELD OF THE INVENTION
The present invention relates to a tumbler type washing/drying machine and a method of controlling the same, and more specifically, it relates to a washing/drying machine which performs various process steps of keeping the washing in wash water, washing, rinsing, dehydrating (extracting water), and drying, and to a method of controlling the washing/drying machine.
DESCRIPTION OF THE RELATED ART
There is a conventionally well-known tumbler type washing/drying machine which performs a series of functions from washing to drying by horizontally rotating a drum containing the washing therein in a tub (e.g., see Japanese Unexamined Patent Publication Nos. 78996/1980 and 12686/1983). However, such a conventional washing/drying machine has disadvantages as follows:
(1) In the step of washing, washing for the washing is processed through the so-called tumbling operation in which the washing is drawn up by an inner wall of the drum and then tumbled down into the wash water. This performance brings about a poor washability, and it needs a washing time double as long as that of a pulsator type full automatic washing machine.
(2) In the step of dehydrating, the tub greatly vibrates due to precession or mutation with high-speed retation of the drum. Therefore, a concrete or iron balancer of about 20 kg must be attached to the tub to restrain the undesired vibration, with a result that the total weight of the machine is made large.
(3) In the step of drying, it is difficult to expose dry air uniformly to the washing all over, and therefore, the washing may partially remain undried, or excessive drying causes the cloth to be damaged easily.
SUMMARY OF THE INVENTION
The present invention provides a washing/drying machine which includes a tub, means for feeding water to the tub, means for draining water from the tub, a tumbling drum rotatably along a lateral axis in the tub, having a plurality of holes through which air and water pass and an opening for introducing the washing, and a lid for closing the opening, means for rotating the drum at various speeds, a disc for agitating the washing, disposed in the drum adjacent to a flat end wall of the drum in parallel with the wall, means for rotatably bearing the disc, means for selectively fixing the disc, means for supplying hot air to the drum and means for controlling the fixing means to intermittently fix the disc against the rotation of the drum.
Preferably, the disc bearing means includes a bearing for rotatably supporting an axis of the disc, and the fixing means includes a clutch for mechanically engaging/disengaging the axis of the disc with/from the tub.
The agitating disc may include a plurality of projections and a plurality of air holes.
Preferably, the drum has an annular rib in the periphery of its circular side wall.
Preferably, the hot air supplying means includes a duct located outside the tub, for communicating both flat end walls of the tub, a blower located in the duct for circulating the air in the tub through the duct, and a heater located at the outlet end of the duct.
Further, preferably, the heater is arched in shape and located on one of the end walls of the tub and above the axis of the drum.
The heater may be accommodated in an arched concavity provided on the side wall of the tub and covered with a cover.
The heater may also be accommodated in a heater case attached to the side wall of the tub.
Preferably, the hot air supplying means further includes cooling means for cooling the circulating air in the duct to dehumidify it.
The cooling means may include a U-shaped air duct.
The drum rotating means may be a DC brushless motor composed of a stator provided with a winding and a rotor including a permanent magnet.
Preferably, an ON-OFF duty ratio of the line voltage applied to the winding of the stator in the washing condition, such as water-extracting and the like, where the motor works at high speed, is made larger than an ON-OFF duty ratio of the line voltage applied to the winding of the stator in the washing condition, such as washing, rinsing and the like, where the motor works at low speed, for controlling the revolution of the motor in accordance with the washing conditions.
The line voltage applied to the winding of the stator of the motor may be subjected to pulse width modulation in order to control the motor speed in a range of the washing conditions.
The present invention provides a method of controlling a washing/drying machine, which includes a tub and a tumbling drum for containing the washing horizontally disposed rotatable in the tub, for performing the steps of washing, water-extracting, and drying, the water-extracting step comprising the steps of storing in advance in storing means a plurality of programs for increasing the rotating speed of the drum by stages with time, loosening the washing by rotating the drum forward and backward alternately, reading the programs corresponding to an amount of the washing contained in the drum from the storing means, rotating the drum in one direction in accordance with the program read out, for gradually pushing the washing against the inner walls of the drum by centrifugal force, detecting a degree of vibration of the tub while the drum is rotating and comparing it with a given or reference value, and rotating the drum at higher speed than a maximum limit rotating speed according to the program to extract water from the washing when the vibration of the tub is smaller than the reference value.
Preferably, when the vibration of the tub attains the reference value in the step of rotating the drum according to the program read out, the drum is rotated forward and backward alternately to loosen the washing after temporarily stopped, and then further rotated according to the same program.
The water-extracting step may further include the steps of feeding the drum with water and then rotating it forward and backward alternately and draining the water from the drum when the vibration of the tub attains the reference value even with a predetermined times of repetitive performance of rotating the drum according to the program after the loosening of the washing.
The present invention also provides a method of controlling a washing/drying machine, which includes a tub and a tumbling drum for containing the washing horizontally disposed rotatable in the tub, for performing the steps of washing, rinsing, water-extracting, and drying, the water-extracting step comprising the steps of storing in advance in storing means a plurality of programs for increasing the rotating speed of the drum by stages with time, loosening the washing by rotating the drum forward and backward alternately, reading the programs corresponding to an amount of the washing contained in the drum from the storing means, rotating the drum in one direction in accordance with the program read out, for gradually pushing the washing against the inner walls of the drum by centrifugal force in a well-balanced condition, rotating the drum at higher speed than the maximum limit rotating speed according to the program to extracting water from the washing, rotating the drum again forward and backward alternately to loosen the washing, rotating the drum in one direction according to the program, and rotating the drum at higher speed than the speed in the previous step to further extract water from the washing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a tumbler type washing/drying machine according to the present invention;
FIG. 2 is a vertical cross-sectional view showing the tumbler type washing/drying machine according to the present invention;
FIG. 3 is a side view showing the left side of the tumbler type washing/drying machine according to the present invention;
FIG. 4 is a frontal elevational view showing the tumbler type washing/drying machine according to the present invention;
FIG. 5 is rear elevational view showing the tumbler type washing/drying machine according to the present invention;
FIG. 6 is a sectional view showing a clutch;
FIGS. 7 to 9 are partial sectional view showing the operation of a major portion of the clutch;
FIG. 10 is a partial cutaway view showing a major portion of the tumbler type washing/drying machine according to the present invention;
FIG. 11 is a sectional view showing a configuration of the fixing of a heater of the tumbler type washing/drying machine according to the present invention;
FIG. 12 is a frontal elevational view showing a heater cover;
FIG. 13 is a frontal elevational view showing a configuration of the heater;
FIG. 14 is a diagram showing a circulating path of hot air;
FIG. 15 is a sectional view showing a dehumidifying heat exchanger;
FIG. 16 is a sectional view showing a major portion of an annular rim;
FIG. 17 is a block diagram showing a control device of the tumbler type washing/drying machine according to the present invention;
FIG. 18 is a sectional view showing a motor for rotating a tumbling drum;
FIG. 19 is a wave form chart showing rotor position signals and driving voltage of the motor;
FIG. 20 is a diagram showing characteristic curves of the torque-revolution speed of the motor;
FIGS. 21(a) and 21(b) are wave form charts of PWM voltage applied to the motor;
FIG. 22 is a diagram showing characteristic curves of the torque-revolution speed related to the duty ratio of PWM;
FIG. 23 is a diagram for explaining a state of the washing in the tumbling drum related to an increase of the rotation speed;
FIG. 24 is a diagram for explaining the relations between the rotation speed of the drum and time for a well-balanced condition;
FIG. 25 is a graph showing curves of the time and temperature in the step of drying;
FIGS. 26 to 28 are flow charts showing the operation of the tumbler type washing/drying machine in the step of drying;
FIGS. 29 and 30 are graphs showing a curve of the heater current related to the temperature variation with time in the step of drying;
FIGS. 31(a)-31(f) are flow charts successively showing the steps of washing, rinsing, dehydrating (extracting water) and drying in the tumbler type washing/drying machine according to the present invention; and
FIGS. 32(a)-32(e) are time charts in correspondence with FIGS. 31(a)-31(f).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described in detail in conjunction with the preferred embodiments shown in the accompanying drawings.
1. Overall Structure of Washing/Drying Machine
FIG. 1 is a perspective view showing a washing/drying machine according to the present invention. Referring to FIG. 1, the washing/drying machine has a cabinet 1, a front panel 2, an upper plate 3, a lid 4, a bottom plate 5, a control panel 6 having various control keys, a program display 7 having a start button, and a power switch 8. FIG. 2 is a vertical cross sectional view showing the washing/drying machine in FIG. 1. FIG. 3 is a side view of the left side of the washing/drying machine, where an inner structure except a part of the cabinet is shown. FIG. 4 is a frontal elevational view showing an inner structure with the front panel removed. FIG. 5 is a rear elevational view showing an inner structure with the cabinet removed. As shown in FIGS. 2 to 5, in the cabinet 1, there are provided a washtub 9, a drain valve 11, a washing drum 12 horizontally and rotatably supported in the washtub 9, a DC brushless motor 13 rotating the drum 12 forward and backward and capable of varying its rotating speed, a agitator disc 15 inside and in parallel with a flat end wall 14a of the drum 12, an electromagnetic clutch 16 selectively bearing the agitator disc 15 in either a freely rotatable state or a fixed state, a duct 17 formed outside the washtub 9 for communicating between two different side walls of the washtub 9, a blower 18 provided in a passage between opposite ends of the duct 17 for circulating air in the washtub 9 through the duct 17, a dehumidifying heat exchanger 19 provided between the opposites ends of the duct 17 for dehumidifying the circulating air in the duct 17 by cooling, a spring hanger 20 for hanging the washtub 9 from the cabinet 1, and a shock absorber 21 for fixing the washtub 9 to the cabinet 1. The drum 12 has apertures 22 over its circular wall and side walls 14a, 14b, through which air and water pass, an opening 23 at the circular wall, through which the washing is introduced and drawn out, and a door 24 for the opening 23. An elastic tube 25 is provided in an upper portion of the cabinet 1, communicating an opening 26 closed by the lid 4 and an opening 27 at the top of the washtub 9 and serving as a guide for the washing introduced into the drum 12. A plurality of baffles 28 are attached at regular intervals in the circular inner wall of the drum 12 to catch the washing while the drum 12 is rotating. The agitator disc 15 has a plurality of projections 29 at regular intervals on its surface and has throughholes 30 all over to which air and water pass. A heater 31 is placed in a juncture of the duct 17 to the washtub 9 for heating air to be fed through the duct 17 to the washtub 9. A heater 32 is placed inside a bottom of the washtub 9 for heating wash water in the washtub 9. The drum 12 has one of rotation axes 33 held by a bearing 34 at the side wall of the washtub 9 with a pulley 35 fixed on its end. The pulley 35 is connected to a pulley 36 on an output shaft of the motor 13 by a belt 37, and is driven by the motor 13. The other rotation axis 40 of the drum 12 and a rotation axis of the agitator disc 15 are coaxially held inside the clutch 16. A closing valve 38 drains cooling water from the dehumidifying heat exchanger 19, while an overflow pipe 39 drains water overflowing from the dehumidifying heat exchanger 19.
A water level sensor S1 is connected to the bottom of the washtub 9 through a air tube for detecting a water level in the washtub (see FIG. 2). A water temperature sensor S2 (FIG. 2) is provided at the bottom of the washtub 9 for detecting the temperature of wash water reserved in the washtub 9. A vibration sensor S3 (FIG. 4) is a sensor having a limit switch which works when the vibration of the washtub 9 becomes a given limit value or over. A flow rate sensor S4 is provided close to a feed valve 10 for detecting an amount of water fed to the washtub 9.
2. Agitator Disc and Electromagnetic Clutch
The agitator disc 15 and electromagnetic clutch 16 will be explained in detail below.
As shown in FIG. 6, the rotation axis 40 of the drum 12 is a sleeve shaft, where an axis 41 of the disc 15 is borne by metal pieces 42, 43 so as to be able to rotate relative to the drum 12. The axis 40 has its flange 44 screwed on the end wall 14a of the drum 12. The axis 41 of the disc 15 has a seal 45 for sealing against wash water, and a clutch boss 46. A bearing holder 47 of a bearing 47a carrying the axis 40 is screwed on a bracked 49 together with a housing 48 extending up to the periphery of the clutch boss 46.
As shown in FIG. 7, the housing 48 has a plurality of concavities 48a positioned at regular intervals in its inner surface, and a retainer 50 is attached between the housing 48 and the clutch boss 46, while cylindrical rollers 51 are rotatably held between the concavities 48a and the clutch boss 46. The cylindrical rollers 51 are always pressed against the clutch boss 46 by a pressing element which is formed integral with or separate from the retainer 50. The retainer 50 has a groove 50a formed on its outer surface, in which a plunger 52a of a solenoid 52 is received so as to prevent the retainer 50 from moving. When the solenoid 52 is energized and the plunger 52a reaches the bottom of the groove 50a, the cylindrical rollers 51 are rotatably retained in the center of the concavities 48a by the retainer 50, and consequently, the agitator disc 15 is rotatably supported by the clutch boss 46 and the metal pieces 42, 43. When the energizing of the solenoid 52 is broken and the plunger 52 is pulled out of the groove 50a, that is, the clutch boss 46 tends to rotate, then the cylindrical rollers 51 are moved by contact of the rotating clutch boss 46 until they are stopped by a wedge action between the housing 48 and clutch boss 46; that is, as shown in FIG. 8 or 9, the cylindrical rollers 51 chock the clutch boss 46 up in the housing 48, and therefore, the disc 15 does not rotate even with the rotation of the drum 12.
Thus, the following effects are attained in the washing step where the drum 12 is rotated:
(1) When the solenoid 52 is turned off so that the disc 15 may be stationary in opposition to the drum 12 on rotating, the projections 29 on the agitator disc 15 act beating and rubbing to the washing, and additionally, the washing tumbles in the three-dimensional way in the drum 12 and jumbles with high efficiency, so that substantially the washing can be washed by friction and pressure caused by the rubbing and crumpling.
(2) When the solenoid 52 is turned on so that the disc 15 may freely move independently of the rotation of the drum 12, the disc 15 moves in accordance with the movement of the washing, so a simple movement of the washing is repeated in the drum 12, that is the washing hangs on the baffles 28, are lifted up and tumbles down. Thus, substantially the washing can be washed by the beating as in the conventional tumbler type washing machines.
The method mentioned in the above paragraph (1) significantly excels the method in (2) in washability. A combination of (1) and (2) attains a uniform washing of every part of the washing, and enables a wide range of regulation in washability.
3. Heater for Drying
The heater 31 is arched in shape, of which center corresponds to the axis of the drum, and located on one of the end walls of the washtub and above the axis of the drum, and its configuration will be explained in detail below.
As shown in FIG. 11, an arched groove 53 is formed facing outside on the upper half of one the end walls of the washtub 9 by means of drawing and others. The arched groove 53 on the washtub 9 may alternatively be formed with a separate heater case fixed to the side wall of the washtub 9 by means of welding or the like. The heater 31 is attached inside the arched groove 53 of the washtub 9. The arched groove 53 having the heater 31 therein has its opening facing to the drum 12 covered with an arched heater cover 54. Air for the drying is heated by the heater 31 in an arched space defined by the arched groove 53 and heater cover 54.
The arched groove 53 has an inlet 53a (FIG. 10) of the air for the drying in its center, and the outlet 53a is connected to an exhaust outlet of the duct 17. The heater cover 54 has outlets 55, 55a of the air for the drying at its arched opposite ends (see FIG. 12). The air outlets 55a at the arched opposite ends may be formed one at each end, or more than one at each end (two at each end in FIG. 12).
The size of the air outlets 55, 55a at the arched opposite ends is determined so that an amount of air for the drying blown out of them may be the same. When two of the air outlets 55, 55a are provided at each of the arched opposite ends, the outlets 55 having a longer air path from the air inlet 53a in the arched groove 53 are larger than the outlets 55a; that is, all of the outlets exhaust the same amount of air as they can. The heater cover 54 is reinforced by forming a diaphragm, folds, ribs or the like and is adapted not so as to be warped because of an attachment to the washtub 9.
The washtub 9 also has an exhaust outlet of hot air in its lower half opposite the position where the arched groove 53 is formed, from which hot humid air after touching the wet washing should be extracted. The duct 17 connect the exhaust outlet to the dehumidifying heat exchanger 19.
FIG. 13 is a diagram showing the heater 31, which is composed of arched heaters 31a, 31b, and 31c having their respective opposite ends fixed to heater flanges 56, and each of the heaters 31a to 31c is solely energized. The heater 31 is fixed to the arched groove 53 on the washtub 9 with packing 57 attached to the heater flanges 56. A plurality of heater supporting angles 58 are fixed to the arched groove 53 by spot welding, and the heater cover 54 is screwed on the heater supporting angles 58.
Air for the drying is fed through an arched path defined by the arched groove 53 on the washtub 9 and heater cover 54 into the drum 12 and traverses the drum 12 as an air flow passing through all over the washing. Therefore, the heated air for the drying dehumidifies the washing without causing a local increase in temperature and without remaining undried part, and thus, the washing can be dried with high drying efficiency. The temperature in the washtub 9 never rise near 100° C. unlike an ordinary tumbler type washing/drying machine, but reaches about 60° C. like a general cloth dryer.
Since the heater 31 is composed of a plurality of arched heaters each of which can be solely energized, a drying temperature for cloth of chemical fiber which must be dried at low temperature can be easily controlled in a considerably wide temperature range by changing a combination of the number of the heaters to be energized. For example, if the heater having the total electric power of 1200 W is composed of three arched heaters having 350 W, 400 W and 450 W, respectively, the heater can be regulated in seven levels in accordance with the combination of energizing the heaters.
4. Dehumidifying Heat Exchanger
Means for feeding hot air to the drum 12 in the drying step is provided outside the washtub 9, as shown in FIG. 14, and it is composed of the duct 17 for connecting one of the side walls of the washtub 9 to the other side wall, the blower 18 for circulating air in the washtub 9 through the duct 17, the heater 31 for heating air to be fed to the washtub 9, and the dehumidifying heat exchanger 19 for dehumidifying air to be exhausted from the washtub 9 by cooling.
The heat exchanger 19 is composed of a U-shaped air duct 60 connecting between a hot air exhaust outlet of the washtub 9 and an inlet of the blower 18, a cooling water spray nozzle 61 placed on the side of air inflow in the air duct 60, a drain outlet 62 formed at the bottom of the air duct 60, and the closing valve 38 (see FIG. 4) for opening and closing the drain outlet 62. To keep a fixed amount of water in the sharp bend 63 of the U-shaped air duct 60, an overflow outlet 64 is formed above the drain outlet 62 and below an wall above the bend 63.
The air duct 60 is positioned on the side of the washtub 9, placing the sharp bend 63 down, and it has a first end on the inlet side connected through the duct 17 to the hot air exhaust outlet of the washtub 9 while having a second end on the outlet side connected to the inlet of the blower 18 in a position higher than the first end. The hot air exhaust outlet of the washtub 9 is positioned at higher level than the level of wash water, serving also as an overflow outlet 64 of the washtub 9.
The cooling water spray nozzle 61 is attached to an upper surface of the first end on the inlet side of the air duct 60 and sprays water from a water supply device downward to have a large area as possible where the cooling water directly touches hot humid circulating air and consequently to take a good cooling effect. Thus, the dehumidifying capability can be enhanced, and additionally, the circulating air is reduced in temperature to prevent cloth from being damaged.
A drain pipe 65 is fitted on the drain outlet 62 and is connected through the closing valve 38 to the drain valve 11. A drain hose 66 (FIG. 4) is connected to the drain valve 11 to lead to the outside. A drain pipe 9 (FIG. 4) provided at the bottom of the washtub 9 is connected between the closing valve 27 and the drain valve 9 to prevent wash water from flowing into the heat exchanger 19 in washing.
The overflow outlet 64 is settled in the position where an area of the water surface in the air duct 60 can be defined large and the air path for the circulating air does not narrow (i.e., there is no large difference between sectional areas taken along segments A and B in FIG. 15). The overflow pipe 39 has one end connected to the overflow outlet 64 and the other end connected to the drain hose 66 on the downstream side from the drain valve 11. The cooling water which has been heated at the end of the heat exchange is always drained out of the overflow outlet 64 no matter whether the machine is energized and further drained through the overflow pipe 39 out of the machine.
A sensor 67 is placed on the inlet side of the air duct 60 while a sensor 68 is placed on the outlet side; both the sensors 67, 68 are temperature sensors for detecting temperature of the circulating air.
The heat exchanger 19 can be provided with a humidity sensor for detecting a dehumidifying state and other devices beside the above-mentioned devices.
Now, a flow of the air for the drying and the cooling water in the drying step in the tumbler type washing/drying machine will be described. When the drying operation is started, the closing valve 38 is closed, while the heater 31, blower 18 and motor 13 are energized.
The circulating air which becomes hot and humid after drying the washing in the drum 12 pass through the duct 17 into the air duct 60, where it touches the cooling water sprayed by the cooling water spray nozzle 61 and further touches the surface of the cooling water kept in the lower part of the air duct 60. Then, the circulating air is condensed and releases humidity, and thereafter, it turns upward into the inlet of the blower 18. Then, the air is fed through the duct 17 to the washtub 9 and further to the heater 31, and is heated again.
The humidity cooled and condensed is drained together with the cooling water through the overflow outlet 64 and overflow pipe 39 out of the machine. In the drying operation, minute floating matter, lint, originated from the washing is also drained out of the washtub 9, and drops down in the water kept in the lower part of the air duct 60 along with the cooling water from the spray nozzle 61. The closing valve 38 is intermittently opened and closed, and accordingly, the water with the lint is drained. The closing valve 38 keeps closed for the most time except the time when the lint is drained with water, and therefore, the cooling water reaches the level of the overflow outlet 64, and the water over the water level is to be drained.
In the drying step, the sensors 67, 68 detect the temperature of the circulating air, and the drying operation is stopped when a difference between the temperatures detected by the temperature sensor 67, 68 is more than the given value.
Positioning the junction between the duct 17 at the inlet of the air duct 60 and the hot air exhaust outlet of the washtub 9 at a higher level than the surface of the rinsing water and at a lower level of the opening 27 for introducing the washing, the water can be drained through the heat exchanger 19 and overflow outlet 64 out of the machine when an abnormal rising of the water level is caused by water level sensor trouble or the like.
During the drying operation, the closing valve 38 keeps closed except the time when it is intermittently opened for a short time. The closing valve 38 may be closed after the operation is ended, but it can be manually opened if it is not used for a long time or if the water in it may possibly be frozen in winter.
The heat exchanger 19 can have the hot air circulating path taking a large sectional area according to the abovementioned configuration. As a result, it can ensures a flow rate of the circulating air by making a pressure loss small, and can take a large contact area of the cooling water with the hot humid air.
In this way, the circulating air sufficiently touches the cloths in the drum 12 and the cooling water. Thus, the drying capability can be improved, and the temperature of the circulating air can remain low.
Making a water pool in the air duct 60, the water surface of the pool can be useful for heat exchange. Thus, a small amount of cooling water is effectively utilized to enhance the dehumidifying capability and to further improve the drying capability. Additionally, in this case, the hot air is directed almost orthogonal to the water surface, and therefore, minute lint in the hot air can be eliminated.
In this way, since almost all lint can be eliminated in the heat exchanger, there is no need of using a special filter and the like and no need of the frequent inspection.
The hot air feeding means composed of the heater 31, dehumidifying heat exchanger 19, blower 18 and duct 17, as previously mentioned, supplies hot air to the washtub 9, and especially, the hot air feeding means is designed so that the hot air can be effectively supplied to the washing in the drum 12 in the washtub 9. As shown in FIG. 16, the drum 12 has an annular rim 69 horizontally projecting on the whole periphery of its wall opposite to the heater 31. The rim 69 is integrally formed with the peripheral wall of the drum 12. A projecting length of the rim 69 is about 80% of an interval between the circular side wall of the drum 12 and the side wall of the washtub 9.
An annular guide 70 projecting toward the drum 12 is attached to the inner surface of the side wall of the washtub 9. The guide 70 is of rubber, and it is composed of a part in contact with the inner surface of the side wall of the washtub 9 and a part projecting contiguous to the previous part, as shown in FIG. 2. The guide 70 has a shape of bellows having the whole inner circular surface of the projecting part wound by reinforcing wire 71 in spiral. The guide 70 has a smaller diameter than the rim 69. The projecting part of the guide 70 has a length of about 95% of an interval between the side wall of the washtub 9 and the circular side wall of the drum 12.
When the hot air heated by the heater 31 is supplied to the washtub 9, the guide 70 on the washtub 9 and the rim 69 of the drum 12 prevent almost all the hot air from flowing toward the circular side wall of the drum 12, but guide the hot air to the throughholes on the side walls of the drum 12 so that the hot air may effectively blow into the drum 12.
5. Control Device of the Washing/Drying Machine
A major portion of a control device of the washing/drying machine is accommodated in an operating unit 6 and a display unit 7 shown in FIG. 2, and its structure is shown in a block diagram of FIG. 17. Referring to FIG. 17, voltage from an A.C. power source is applied through the power switch 8 to a driving circuit 73, a rectifying circuit 74 and a motor control circuit 75 for controlling the brushless motor 13. A microcomputer 76 starts when receiving D.C. voltage from the rectifying circuit 74. The microcomputer 76 receives output from the control unit 6, water level sensor S1, water temperature sensor S2, temperature sensors 67, 68, vibration sensor S3, flow rate sensor S4 and motor control circuit 75 to output a signal for controlling the program display 7, feed valve 10, drain valve 11, closing valve 38, heater 31, hot water heater, solenoid 52 and blower 18 to the driving circuit 73 and output a signal for controlling the brushless motor 13 to the motor control circuit 75.
6. Motor Control for Controlling Revolving Speed of Drum
As previously mentioned, the drum 12 is driven by the revolving force transmitted from the DC brushless motor 13 through the pulley 36 and belt 37 to the pulley 35.
The motor 13 requires a large torque to lift up the washing soaked with wash water in washing and requires high speed revolutions in water-extracting. More specifically, the motor 13 must implement a large torque (about 38 kg.cm) and a low speed (about 400 rpm), and a low torque (about 2.5 kg.cm) and a high speed (about 8000 rpm).
The structure of the motor 13 will be described with reference to FIG. 18.
A permanent magnet 77 of a rotor 78 is made of ferrite and has a ring-like shape, having eight magnetic poles. The rotor 78 is borne by the bearing 79 and fixed to the motor case 80 in freely revolving condition, while a stator 81 is wound by winding so as to make three phases and fixed to the motor case 80.
The D.C. voltage produced from supply voltage of the power supply 72 by the rectifying circuit 83 is distributed in a transistor module 84 to drive the motor 13 in three-phase.
The revolution angle position of a rotor of the motor 13 is detected by three hole sensors 82 and applied to the microcomputer 76, which performs arithmetic operations therein to output base control signals of the transistor module 84 of the three phases. The signals are subjected to pulse width modulation in a PWM circuit 85 for controlling the number of revolutions and amplified in a base drive circuit 86, and thereafter, turn the transistor module 84 on.
Now, with reference to FIG. 19, a timing chart for producing the base signal of each phase of the transistor module 84 in accordance with a rotor position signal by the arithmetic operations performed in the microcomputer 76 will be described. In this embodiment, the ON-OFF duty ratio of a line voltage pattern applied to the winding of the stator of the motor is one third in the low speed operation but one half in the high speed operation.
The rotor position signal is detected at each pole of the permanent magnet 77 (for example, there are eight poles in this embodiment, so one cycle corresponds to 90°) by the three hole sensors 82 settled in predetermined positions of the motor 13. Three rotor position signals from the three hole sensors 82 are designated by (1), (2) and (3), respectively.
The base control signal varying with the revolution of the rotor in the counter clockwise direction (CCW) in the low speed operation (indicated by solid line), if it is a U-phase signal, is turned ON when the rotor position signal (1) falls, and is turned OFF as the rotor is retained at an angle 30°. In this way, the total ON-OFF duty ratio becomes 1/3. Similarly, V- and W-phase outputs are controlled with reference to the falling of the rotor position signals (2) and (3).
X-, Y- and Z-phase outputs are controlled with reference to the rising of the rotor position signals (1), (2) and (3).
For a ON- time with the rotor angle of 30, if the U-phase signal is employed as an example, the rising of the rotor position signal (2) is detected and some processing is performed to turn it off.
In the high speed operation (indicated by broken lines), the signal output is controlled to turn on a rotor angle 15° earlier than the case in the low speed operation, and thus the total ON-OFF duty ratio becomes 1/2. Practically, employing the U-phase signal as an example, the rising of the rotor position signal 2 is the reference.
While the base signal varying with the revolution of the rotor the clockwise direction (CW) is being turned on, the reference of the falling of the signal varying with the revolution of the rotor in the CCW direction becomes the reference of the rising. The order of the turning-off time of the U-, V- and W-phases and the X-, Y- and Z-phases is reversed; if the references of the rising and falling are reversed, the result is shown in FIG. 19, where a motor characteristic similar to the signal varying in the CCW direction can be observed.
Then, the motor measured characteristic when the motor works in accordance with the timing chart in FIG. 19 will be explained with reference to FIG. 20. In FIG. 29, points A and B are operating points for the tumbler type washing/drying machine according to the present invention. Solid line expresses a control characteristic in the low speed operation, while broken line expresses it in the high speed operation.
Referring to FIG. 20, it is apparent that the method of controlling in the high speed operation satisfies the requirement for both the operating points. However, the operating point A of the washing is an operating point for the case where the drum just starts or the clothes are entangled with each other, and it attains 400 rpm, one third or below of the maximum torque in practical operation. This method has the disadvantage that the motor must be large-sized because if the control method is applied not to the low speed operation which needs small consumed current but to the high speed operation which needs large consumed current, heat generated by the motor is too large.
Although the generation of heat can be inhibited with a permanent magnet of rare earth elements or the like because magnetic force becomes stronger, such a magnet of rare earth elements about twenty times as much in price as a ferrite magnet, and it is difficult to employing the magnet of rare earth elements for electric appliances.
Unlike the washing operation, a load torque does not vary once the drum starts revolutions at the point B in accordance with the method of controlling the high speed operation. A torque the motor requires corresponds to an amount of friction of a revolving mechanism when the accelerating period for revolutions ends, so consumed current is small even with the ON-OFF duty ratio of 1/2, and there is no possibility that the motor generates heat.
This is why a cheap magnet having low magnetic force allows the motor to attain from a great torque at low speed to high speed revolutions without speed changing means.
Now, a method of controlling the number of revolutions of the motor will be explained with reference to FIGS. 21 and 22.
It has been described that the operating points A and B in FIG. 20 is in a range of the power of the motor and that the drum can be rotated. In practical operation with the revolution speed predetermined, the power of the motor must pass the operating points. FIG. 21 shows a waveform in which the output base signal shown in FIG. 19 is subjected to pulse width modulation, where a duty ratio is about 2/3 in a waveform (a) while it is about 1/3 in a waveform 8b). As shown in FIG. 22, as the duty ratio of PWM becomes smaller, the power decreases to have a curve drawn in lower position.
While the motor 13 is working, the microcomputer 76 always inspects a state of the rotor position signal shown in FIG. 19. In this embodiment, if the revolution speed is set a single turn per second, the duty ratio of PWM is controlled to be increased or decreased so that the cycle of the rotor position signal becomes 1/4 second (this is because the motor make a turn in four cycles).
If a rotor position signal pulse is not inputted after 1/4 second obtained by calculation elapses, the microcomputer 76 decides that a too large load delays the revolution of the rotor, and it applies a higher duty ratio of the output base signal next time. On the contrary, if the pulse is inputted before the 1/4 second elapses, the microcomputer 76 decides that the rotor rotates too fast, and it applies a lower duty ratio of the output base signal next time.
In this way, the power of the motor always passes the operating point of a load, and hence, the motor keep a predetermined speed of revolutions in spite of the variation in a load torque.
Thus, the drum 12 can perform a non-stage transmission in a wide range of speed.
7. Revolutions of Drum and Balance Control
The drum 12 is cylindrical in shape, and is rotated forward or backward at the specified number of revolutions by the motor 13, as previously mentioned.
In the washing step, the washing operation is performed under control of the program (for the tumbling washing) according to which the drum 12 is rotated with the rotation speed ωs smaller than the critical rotation speed ωo at which the washing is tumbled, under control of the program (for the light cleaning washing where the washing laying against the wall of the drum is soaked in wash water) according to which the drum 12 is rotated with the rotation speed ωh larger than the critical rotation speed ωo, or under control of the program (for the high washability washing) according to which the drum 12 causes the washing to be tumbled with the agitator disc 15 fixed and with outer force (physical force) being applied to the washing to enhance the washability.
The gravitational acceleration is well-balanced with centrifugal force, and this leads to an equation mg=mrωo 2 . In accordance with the equation, the critical rotation speed (angular velocity) ωo is calculated as follows: ##EQU1## where m denotes a quantity of the washing, r denotes a radius of the drum and g denotes a gravitational acceleration.
The rotation of the drum 12 with the rotation speed higher than the critical rotation speed (angular velocity) ωo causes the washing to be pushed against the inner circular wall of the drum 12 in some distribution state. Uneven distribution of the washing in the drum, uneven distribution of the washing results in the center of gravity of the composite quantity of the washing deviating from a horizontal axis of the drum, and this causes the drum to vibrate, and this also causes the washtub 9 having the motor 13 and the like to vibrate.
An amplitude X of the vibration of the washtub 9 is obtained in accordance with the following equation: ##EQU2## where m A is an unbalance quantity, ω is a rotation speed of the drum, ω is a proper frequency, ξ is an attenuation ratio, and M is a total mass of a vibrator.
In accordance with the above formula, it is apparent that as the total mass M increases, the vibration (amplitude) becomes small. In practical use, it is possible that a concrete block or an iron block is attached to the washtub 9 as a vibration proofing weight and the total mass M is made larger so that the vibration may be reduced. However, this method is not preferable because of the disadvantage that the resultant product has an undesirable large weight.
In the present invention, the revolution speed of the motor 13 can be set arbitrarily, and so it is possible to make the vibration caused by the rotation of the drum 12 (ω>>ω 0) close to the vibration when the drum contains no load by gradually increasing the rotation speed of the drum 12 and unifying the distribution of the quantity of the washing in the drum 12 (the center of gravity of the composite quantity of the washing distributed in the drum is positioned corresponding to the horizontal axis of the drum). The washing in the drum 12 is gradually push against the inner circular wall of the drum 12 as the drum 12 revolves faster, and soon the washing makes a distribution in the shape of a ring. FIGS. 23(a) to 23(e) show the stages of making the distribution.
In the dehydrating step, as shown in FIG. 23, since the washing tumbled in the drum 12 is gradually push against the inner circular wall of the drum as the drum revolves faster, the diameter of the drum (inner diameter of the ring of the washing) becomes apparently smaller, and eventually, all the washing lie against the inner surface of the circular wall of the drum 12. When the distribution of the quantity of the washing is good, the center of gravity of the washing distributed along the inner circular wall of the drum 12 corresponds to the axis of the drum 12; this means a balanced state in which only considerably slight vibration occurs even in the centrifugal water-extracting (the rotation speed of the drum is 800 to 1000 rpm.).
Thus, the rotation of the drum 12 when the dehydrating operation is started varies from the low speed rotation (about 50 rpm) to the rotation speed (about 130 rpm) lower than both the resonance rotation speed of the washtub 9 and the high speed rotation in correspondence with the capacity for the washing in accordance with a balance chart shown in FIG. 24 in which the rotation speed of the drum 12 and the rotation time at the rotation speed are preset.
In this case, when the vibration of the washtub 9 which is detected by the vibration sensor S3 is an allowable value or under, the drum 12 continuously proceeds to the high speed rotation (e.g., 800 to 1000 rpm); contrarily, when it is more than the allowable value, the drum 12 is temporarily stopped, or it switch to the low speed rotation (cloth of the washing is loosened) and thereafter works in accordance with the balance chart in FIG. 24 again. If the vibration of the washtub 9 does not reach the allowable value or under even when this operation is thoroughly repeated a specified number of times (e.g., three times), the drum 12 is controlled to start with the rinsing operation again.
On the other hand, when the dehydrating operation just before the drying step is started, the drum 12 does not proceed to the maximum speed rotation (800 to 1000 rpm) even if the high speed rotation of the drum 12 causes the washtub 9 to vibrate at a level of the allowable value or under, but the drum 12 is rotated with the intermediate rotation speed (500 rpm) between the resonance rotation speed of the elastically supported washtub 9 and the high speed rotation speed of the drum 12 for a relatively long time (10 seconds or over, for example) so that the water-extracting efficiency may be 45% or so. After that, the rotation of the drum 12 is temporarily stopped, and then the drum 12 proceeds to the maximum speed rotation in accordance with the previously mentioned process.
When the dehydrating operation just before the drying step is performed in accordance with the above-mentioned process, there are advantages over the case in which water is rapidly extracted from the wet washing by utilizing centrifugal force as in the ordinary dehydrating step; that is, the washing can be prevented from tightly lying against the inner circular wall surface of the drum 12, the washing can be easily tumbled when the process proceeds t the drying step to enhance the drying efficiency, and the washing finished in the drying operation is wrinkled at a lower rate.
The capacity for the washing is detected by the water level sensor S1 and flow rate sensor S4. For example, water is supplied to a predetermined water level after the washing is introduced in the washtub, and thereafter, the washtub is rotated at low speed for a predetermined period. After that, water is further supplied to the predetermined water level to detect the capacity in accordance with an amount of the water supplied at that time. The capacity shown in FIG. 24 is classified into "small" for 1 to 2 kg, "medium" for 3 to 4 kg and "large" for 5 to 6 kg when the maximum capacity is 6 kg, for example.
8. Control of the Drying Operation
In the control device shown in FIG. 17, when the heater 31, blower 18 and motor 13 are energized, the drum 12 revolves while it is fed with hot water, and thus the drying operation starts. In the drying process of the washing in the drum 12, temperature "ta" detected by the temperature sensor 67 and temperature "t" detected by the temperature sensor 68 vary as shown in FIG. 25. Specifically, the temperatures "ta," and "t" gradually rise at the beginning, and soon the temperatures assume an increment Δt≈0 (constant rate period). When the constant rate period ends, the temperature "ta,", "t" begin to rise again, and if it is left as it is, the washing is excessively dried. Therefore, when a difference ΔT between "ta" and "t" attains a predetermined value, the energizing the heater 31 may be stopped to complete the drying. Conventionally, the excessive drying condition is intentionally maintained to prevent the washing from partially remaining undried.
In the present invention, however, the agitator disc 15 is fixed in opposition to the rotating drum 12 to stir the washing, or an arithmetic operation is performed about a signal of the temperature sensor 67 to control a current value of the heater 31 for preventing temperature from rising. Consequently, the washing can be dried well, and there is no possibility of excessive drying and excessively high temperature.
The drying operation will be further explained in detail with reference to the flow chart shown in FIGS. 26 and 27.
First, when the heater 31 is energized (Step 301) and the temperature "t" begins to rise, the temperature variation rate Δt is detected, which is stored as Δtu in the microcomputer 76 (Step 302). When the constant rate period set in, the temperature t does not vary (Δt≈0), the constant rate temperature is stored as CT (Step 303). When the variation rate of temperature Δt (>0) is detected after the constant rate period changes at a constant temperature for a while (Step 304), the microcomputer 76 control (reduce) the current to the heater 31 (Step 305). Then, a condition of the temperature t is checked at Steps 306, 307 and 308, and the process proceeds to the drying completing step (Step 309) immediately or after the drying operation is continually completed for a predetermined time (Step 310), depending upon the condition of the temperature variation in the previous checking steps.
When a disturbance (a state in which the washing in the drum 12 is temporarily put to one side and tumbled) causes the temperature to temporarily rise for the constant rate period, the temperature t quickly drops due to the reduction of thermal power of the heater 31 to a lower value than CT stored in the microcomputer 76. Then, the thermal power of the heater 31 is increased (recovered) (Step 311), and it is checked whether the detected temperature t recovers to CT stored in the microcomputer 76 (Step 312). After that, Step 304 is implemented while the drying is advanced under control. In this way, eventually imperfect drying and excessive drying can be avoided.
In the ironing course, sometimes the drying must be completed attaining a drying efficiency the user desires, as shown in FIG. 27 (Steps 313a, 313b, 313c and 313d). At this time, the operation is controlled so that the thermal power of the heater 31 may be intentionally changed (Step 314), and after the variation rate Δt in temperature is stored as Δtd in the microcomputer 76 (Step 315), the current supplied to the heater 31 is recovered (Step 316).
When the temperature is recovered, the drying efficiency is controlled in accordance with fuzzy inference and fuzzy control, comparing the variation rate Δt with Δtu stored in the microcomputer 76, and the operation is completed. (Steps 313a, 313b, 313c and 313d). F1, F2, F3, and F4 are measured values which are experimentally obtained using devices in this embodiment.
In this embodiment, when the non-tumbling drying course (the drying by rotating the drum with the critical rotation speed or over) is selected, uneven drying is easily caused especially when less load is charged, and moreover, the constant rate period is short; the temperature t varies in a short period. In this case, when Δt>0 is detected, the rotation speed of the drum 12 is reduced to ω<ωo (critical rotation speed), the drum 12 tumbles the washing therein to vary the distribution of the clothes, and then the drum 12 is rotated with the non-tumbling rotation speed (ω>ωo) again for advancing the drying stage). The variation in the rotation speed is automatically repeated until the drying is completed. The power of the heater 31 can be selected among HIGH, MEDIUM, LOW depending upon a kind and quantity of the load in advancing the above-mentioned drying operation.
The non-tumbling (ω>ωo) drying will be described in detain in conjunction with a flow chart in FIG. 28 below.
First, the heater 31 is turned ON (Step 440), the drum 12 is rotated in non-tumbling (ω>ωo) (Step 441), and thus, the non-tumbling drying process starts. The microcomputer 76 performs arithmetic operations based upon load data in the washing process (capacity for the load, quality of the cloth, quantity of rinsing water, water-extracting efficiency, etc.) and manually input data to infer an approximate drying time, and the power of the heater 31 is selected among HIGH, MEDIUM and LOW (Step 442). An increase in temperature of the washing is detected (Step 443), the temperature rising rate Δtu is stored in the microcomputer (Step 444). A temperature variation at the ensuing time is detected (Step 445); if it becomes almost constant, the constant rate temperature CT is stored in the microcomputer 76 (Step 446). A temperature variation at the ensuing time is observed (Step 447); if a temperature rising is recognized, the drum 12 repeats the programmed operation several times, under control with the tumbling rotation speed (Step 448), and thereafter, it revolves with non-tumbling rotation speed again (Step 449). In the ensuing time, the Steps 447 to 449 may be repeated.
The ensuing steps are performed under control in accordance with Steps 304 to 312 shown in FIG. 26, and thus the drying is completed.
FIG. 29 shows a temperature variation in the washing and related current value in the ordinary drying operation. When a temperature variation at the end of the drying operation is detected and a current value to the heater 31 is decreased, the drying is completed in accordance with Steps 306, 307, 308, 309 and 310 in FIG. 26.
FIG. 30 shows a current variation and temperature variation when the current value of the heater 31 is intentionally reduced to check the drying efficiency (Step 314 to 316 in FIG. 27) and also shows a state in which the temperature automatically reaches a temperature at the end of the drying operation after the first current variation. Sometimes, intentionally the current is automatically varied several times to pre-estimate the desired drying efficiency.
9. Continuous Operation from Washing to Drying
Continuous operation steps of washing, dehydrating and drying in the washing/drying machine according to the present invention will be explained in conjunction with flow charts in FIGS. 31(a)-31(f) and timing charts in FIGS. 32(a)-32(e).
When the power switch 8 and start key of the operating unit 6 are turned on, the feed valve 10 is energized and water supply is started (Steps 101 to 103). When a water temperature is set in the operating unit 6, the hot water heater 32 is energized until the water temperature reaches the preset temperature (Steps 104 to 107). Next, when "keeping the washing in wash water before washing" is preset in the operating unit 6, "keeping in wash water before washing" is carried out for a predetermined period (60 minutes) (Steps 108 to 110). At this time, as shown in FIG. 29, the agitator disc 15 is in free rotation condition to revolve forward at 50 rpm. Then, the "washing" is carried out for a predetermined period (12 minutes), and as shown in FIG. 32(a), the drum 12 repetitively revolves forward and backward alternately, and the agitator disc 15 is intermittently fixed (Steps 111, 112). Next, the rinsing operation is performed. In the rinsing operation, first water is drained, and then, the drum 12 is rotated forward and backward alternately at 50 rpm several times to loosen the clothes (Steps 113, 113a). Then, the drum 12 is rotated in one way, and the rotation speed of the drum 12 is increased in stages from 50 rpm to 130 rpm to regulate the balance (Step 113b). If the vibration of the washtub 9 is a given value or under (Step 113c), the drum 12 is rotated at 400 rpm for 20 seconds to perform "intermediate water-extracting" (Step 114). Then, water is supplied (Step 115), and the drum 12 is rotated forward and backward alternately at 50 rpm several times to rinse the washing (Step 116). As the operation including the Steps 113 to 116 are repeated three times, water is drained (Step 118), and thus, the operation proceeds to the draining step. At Step 113c, unless the vibration of the washtub 9 is the given value or under, the operation including the Steps 113a to 113b is repeated four times at most, and after the fourth performance is completed, the rinsing operation in accordance with Steps 146 to 148 is performed. If the rinsing operation in accordance with the steps 146 to 148 is repeated twice (Step 149), it is recognized that it is difficult to control the vibration of the washtub 9 to the given value or under, and the operation is interrupted and the display unit 7 indicates "ABNORMAL" (Steps 150, 150a).
In the dehydrating operation, the drum 12 is rotated forward and backward alternately several times at 50 rpm for 35 seconds to loosen the clothes (Step 119). The rotation speed of the drum is increased in stages from 50 rpm to 130 rpm to regulate the balance. If the vibration of the washtub 9 is a given value or under, the drum 12 is rotated at 500 rpm for two minutes to perform "low speed water-extracting" (Steps 120 to 122). "Loosening the clothes" and "regulating the balance" are carried out again, and if the vibration of the washtub 9 is a given value or under, the drum 12is rotated at 800 to 1000 rpm for 300 seconds to perform "high speed water-extracting" (Steps 113 to 126). At Step 121, unless the vibration of the washtub 9 is the given value or under, the operation including the Steps 119 to 120 is repeated four times at most, and the fourth performance includes the rinsing steps, Steps 140 to 142. If the rinsing operation in accordance with the Steps 140 to 142 is repeated twice, it is recognized that it is difficult to control the vibration of the washtub 9 to the given value or under, and the operation is interrupted and the display unit 7 indicates "ABNORMAL" (Steps 144, 144a).
As the "high speed water-extracting" at Step 126 is completed, the drying operation is carried out. In the drying operation, the heater 31 and blower 18 are energized, hot air is supplied to the drum 12, a temperature control of the hot air is carried out, and the drum 12 is rotated forward and backward alternately while the agitator disc 15 is fixed or released as shown in FIG. 32(e) (Steps 127, 128). When the drying operation is completed (Step 129), the energizing of the heater 31 is stopped (Step 130), cooling air is supplied to the drum 12 until the temperature detected by the temperature sensor 68 falls to a given value or under to perform "cooling down" (Steps 131, 132), and thus, the process is thoroughly completed.
10. Comparison Test of This Embodiment with Prior Art Embodiment
With regard to the basic performance from the washing to the drying, the results of a comparison test of this embodiment with a prior art embodiment is shown in the following Table I.
TABLE I______________________________________ THIS PRIORITEMS EMBODIMENT ART______________________________________WASHING PERFORMANCEWASHABILITY RATIO 1.1 0.86WASHING CAPACITY 6.0 4.5WASHING TIME 12 26RINSING PERFORMANCE 16 16REMAINING ABS CON-CONCENTRATION (ppm)DEHYDRATINGPERFORMANCEWATER-EXTRACTING 60 57-59EFFICIENCY (%)TUB VIBRATION 7.0 12-20AMPLITUDE (mm)CABINET VIBRATION 2.1 2.5AMPLITUDE (mm)DRYING PERFORMANCEDRYING EFFICIENCY (%) 60 46-51DRYING TIME (min/kg) 41 44-52______________________________________
A method of the test is in accordance with Japanese Industrial Standard, JIS C 9606 and JIS C 9608. With regard to the temperature of the outer wall of the washtub, the inside of the drum and the cabinet, it was recognized that about 30° deg lower in this embodiment than in the prior art embodiment. | A washing/drying machine including a washtub, a feeding device for feeding water to the washtub, a draining device for draining water from the washtub, a tumbling drum, rotatably supported by a lateral axis in the washtub, having a plurality of holes through which air and water pass and an opening for introducing the washing, and a lid for closing the opening, a motor for rotating the drum at various speeds, a disc for agitating the washing, disposed in the drum adjacent to a flat end wall of the drum in parallel with the wall, a bearing device for rotatably bearing the disc, a fixing device for selectively fixing the disc, a device for supplying hot air to the drum, and a controller for controlling the fixing device to intermittently fix the disc against the rotation of the drum, and a controlling method thereof. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for the remote-controlled closing of the gasoline vent of a motor vehicle.
2. Description of the Prior Art
The known processes include locking the external portal or access vent to the gasoline reservoir plug either by means of a lock with a special key or by means of an electric, electromagnetic or pneumatic activator which incorporated in the wiring box of the body and is remotely controlled from centralized command points at the dashboard or in combination with commands for locking the doors and other vehicle openings.
In this case, the activator is mounted in the immediate vicinity of the vent and has a protruding plunger core which locks the filler which is part of the interior wall of the portal.
Such closing presents particular manufacturing difficulties, essentially of three types:
1. Failure of the circuit and/or the activator must be considered a possibility and provided for so the gasoline vent can be opened.
2. The locking system which communicates with the wiring box of the vehicle must not allow gasoline vapors to escape from the reservoir.
3. The locking process must be efficient and not fail upon efforts to break it.
The purpose of the invention is to resolve these difficulties by proposing a particularly carefully studied procedure for locking, preventing the escape of vapors to the rest of the body, and providing emergency command.
To that end, the invention deals with a device for the remote-controlled closing of the gasoline vent of a motor vehicle by means of an activator mounted inside the body and which has a movable core connected with the bolt and capable of locking an interior keeper which is part of the portal to the vent.
In the device the bolt slides through the interior cup of the vent through units for preventing vapor escape and for guiding, both of which fit tightly around the bolt; the keeper is formed by a stirrup which consists of a stud hole ending in a blind housing; and the bolt-activator connection is effected by means of a rod connected to the activator core through an intermediate manual command button which is accessible from inside the vehicle.
As a whole, this system constitutes a simple and easily-mounted closing device which meets the safety demands of current vehicles.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIGURE provided represents a longitudinal cross section of the closing device in the unlocked state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The device is installed near the gasoline vent 1, inside the body 2 and parallel to the pivoting portal 3, giving access to the reservoir plug (not shown). The device consists basically of an activator 4, which may be electromagnetic, which is attached to the sheet metal of the wheel well 5, a sliding bolt 6 moved from a distance by extending the rectilinear movement in either direction of the activator core 7, and a keeper 8 attached on the inside wall of the portal 3.
Moved in the closing direction, the bolt 6 crosses the cup 9 in order to lock the keeper 8 in a self-evident manner.
In accordance with a primary characteristic of the invention, the bolt 6 is a simple blade whose movements through the cup 9 are guided by a perforated plug 10 made of plastic, which obstructs the large opening 11 in the cup, and which features a vapor retention bellows 12 made of an elastic material between the plug and the sheet metal of the cup.
To ensure better guiding, the plug 10 is extended toward the activator by a sleeve 13 surrounding the bolt and molded of a piece with the plug 10.
Preventing the escape of gasoline vapors from the reservoir is accomplished effectively by means of an elastic bellows 14 surrounding the end 15 of the bolt beyond the guide sleeve 13.
The bellows 14 has a small collar at each end, one of which 16 is tight around the end of the sleeve, which has a retaining flange 17, and the other 18 is tight around the end of the bolt, pushing against the hook 19 in the connecting rod 20 between the bolt 6 and the activator core 7.
In accordance with a second characteristic of the invention, a manual emergency command button 21 is attached on the activator-bolt connection. Thus in the event the electric circuit or any mechanical part of the device should fail, the driver can manually override in order to close or unlock the vent by operating lever or button 21, accessible from inside the vehicle.
In the case, for example, of a vent located at the rear of the vehicle and an activator mounted at the level of the rear wheel well, the button 21 would in this case be accessible through the trunk 22 through an opening 23 in the side wall of the trunk and covered by a discrete removable plate 24.
This makes it easier to understand the need for resistance to gasoline vapors described above, particularly because of the connection with the passenger compartment of the vehicle.
The connecting rod 20, which may be quite long, is hooked as seen 19 through the end 15 of the bolt.
The other end of the rod is connected to the protruding end of the activator core 7 through the manual command button 21, one end of which forms a fastening clip 25 and at the same time plays the role of an assembly unit. To show the fastening, the button 21 has deliberately been rotated a quarter turn in relation to the plane of the cross section in the drawing, but in operation the lower part of the button is parallel to the body 2.
According to another characteristic of the invention, the keeper 8 riveted at 31 to the interior wall of the portal 3 consists of a stirrup, preferably of molded plastic, having on one of its hairpin like surfaces a stud hole 26 centered on the bolt 6.
For closing, the bolt goes in the stud hole and ends up in the blind housing 27 of the keeper. The end 6 of the bolt is rounded off to facilitate this introduction.
The boxed form 27 of the keeper improves security, for after locking the end of the pin is not accessible from outside even after introducing a tool in the gap 28 between the portal 3 and the body 2.
Furthermore, the slightly conical shape of the stirrup 8 and the placement of the mounting point 31 of the keeper moved toward the bend in the portal make it possible automatically to close the vent 3 even if the bolt 6 is already in the locked position (dotted lines).
Indeed, one then relies on the strength of the blade of the bolt 6 and on the elasticity of the keeper 8 and the portal 3.
Electronic command of the activator is carried out in a conventional manner by means of an isolated commutator or in combination with the electromagnetic locks for the other points of access to the vehicle, represented schematically here by a key allowing current to be applied as chosen to either the closing circuit 29 or the opening circuit 30 of the different activators, among which is the gasoline vent.
Furthermore, it is worthwhile to provide for an inertial contact which ensures the opening of the activators in the event of a collision as well as for a thermal fuse to protect the circuits and the activators against overheating.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | The bolt (6), brought into play by a remote-controlled activator (4), goes into a keeper (8) shaped like a blind stirrup made in the same unit as the portal (3) by passing through the cup of the vent through intermediary fixtures for guiding (13) and for preventing the escape of gasoline vapors (14). An emergency manual control button (21) is provided on the connection between the bolt (6) and the activator core (7). | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Provisional U.S. Patent Application Ser. No. 60/938,638, filed on May 17, 2007 and incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a spinal compressor instruments and spinal distractor instruments and more particularly to an instrument combining the compression and distraction functions.
BACKGROUND OF THE INVENTION
[0003] In order to perform a surgical procedure in which the separation of various physical components, such as spinal vertebrae, is required, a tool called a distractor is necessary for displacing the physical components from one another. The distractor operates by mechanically converting a compressive force exerted by an individual on a handle located at one end of the distractor into an opposite expanding movement for a pair of engagement tips of the distractor disposed opposite the handle. To accomplish this, the distractor is formed with a number of mechanical linkages that extend between the handles and the distractor tips. These linkages are pivotally connected to one another in a manner that converts the inward movement of the handles into outward movement of the distractor tips.
[0004] In other situations or surgical procedures it is necessary to compress physical components towards one another. In these procedures, it is necessary to employ a tool called a compressor that operates by mechanically converting a compressive force exerted by an individual on a handle located at one end of the compressor into a corresponding compressive force for a pair of engagement tips on the compressor disposed opposite the handle. To perform this function, the compressor is most often formed with a simple scissors linkage such that an inward and compressive force on the handle is translated into an inward compressive force on the compressor tips.
[0005] However, in many surgical procedures both a compressor and a distractor are necessary for proper completion of the procedure, and often times are utilized in the same location in which the procedure is performed. Because the compressor and the distractor are formed as separate tools, it is necessary to have both a compressor and a distractor available such that each tool can be utilized when required during the surgical procedure. For this reason, many kits for use in spinal procedures include both a compressor and a distractor in them. However, the requirement for having compressor and distractor tools present during a procedure can create problems with regard to a number of tools present during a surgical procedure, especially when one of the tools becomes contaminated, i.e., is dropped, and needs to be sterilized.
[0006] As a result, it is desirable to develop a tool that can function as both a compressor and a distractor depending upon the particular situation in the surgical procedure being performed.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the present invention, a tool is provided that can function as either a compressor or a distractor depending upon the operative configuration of the tool. The tool is formed with a pair of engagement tips pivotally connected to a central member such that the tips can be moved laterally towards and away from one another due to the pivoting movement of the pivot arms with regard to the central member. Opposite the tips, the tool includes a pair of handles also pivotally connected directly to the central member for movement with respect to the central member. A central shaft is slidably disposed within and extends through a channel formed in the central member, such that opposite ends of the shaft are positioned between the tips and the handles. Between the tips, the shaft includes pairs of pivoting members connected to the shaft at one end and to the tips at the opposite end of each pivoting member. Between the handles, the shaft includes a saddle slidably mounted to the shaft and pivotally connected to the handles at locations spaced from the central member by additional pivot members. The saddle can be selectively engaged with the shaft at various locations on the shaft to position the saddle in either a before center or an over center location on the shaft. By moving the saddle between these locations, the tool is capable of mechanically translating the compressive force exerted on the handles into either a compressive or distraction force on the tips.
[0008] According to another aspect of the present invention, the handles are connected to one another opposite the central member by an adjustable locking rod. The rod includes a spring-biased locking member that can be engaged with slide extending between the handles when the handles are positioned at any configuration along the slide with respect to one another.
[0009] Numerous other aspects, features, and advantages of the present invention will be made apparent from the following detailed description together with the drawings figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The drawings illustrate the best mode currently contemplated of practicing the present invention.
[0011] In the drawings:
[0012] FIG. 1 is an isometric view of a convertible compressor/distractor tool constructed according to the present invention in a distraction configuration
[0013] FIG. 2 is a side plan view of the tool of FIG. 1 ;
[0014] FIG. 3 is a partially broken away side plan view of the tool of FIG. 1 ;
[0015] FIG. 4 is a partially broken away side plan view of the tool of FIG. 1 in an engaged position;
[0016] FIG. 5 is an isometric view of the tool of FIG. 1 in a compression configuration;
[0017] FIG. 6 is a side plan view of the tool of FIG. 5 ;
[0018] FIG. 7 is a partially broken away side plan view of the tool of FIG. 5 ; and
[0019] FIG. 8 is a partially broken away side plan view of the tool of FIG. 5 in an engaged position.
DETAILED DESCRIPTION OF THE INVENTION
[0020] With reference now to the drawing figures in which like reference numerals designate like parts throughout the disclosure, a convertible compressor/distractor tool constructed according to the present invention is indicated generally at 10 in FIGS. 1 and 2 . The tool 10 includes a pair of tip members 12 at one end, each including a tip 14 and a body 16 extending from the tip 14 . The tips 14 can be integrally formed with the body 16 of each tip member 12 , or can be releasably secured thereto utilizing any suitable mechanism. The tips 14 can additionally be formed from materials different from that used in forming the body 16 , which normally is a metal, such as stainless steel, such that the tips 14 can be formed from plastics, such as transparent plastics that enable an individual to view objects through the tips 14 when the tool 10 is in use. Further, the releasable attachment of the tips 14 to the body 16 of the tip members 12 allows the tips 14 to be removed and replaced should they become damaged.
[0021] Alternatively, the tool 10 can include only a single movable tip member 12 , with the tip member 12 movable with respect to a stationary member (not shown) to provide the compression or distraction function.
[0022] Referring now to FIGS. 4-7 , the tip members 12 are each pivotally connected by a pivot pin 18 to one end of a pair of the first pivot arms 20 . Opposite the tip members 12 , the pair of first pivot arms 20 are each pivotally connected by pivot pins 22 to a supporting central member 24 . However, in addition to pins 22 , the first pivot arms 20 can also be pivotally connected to the tip members 12 with other structures, such as members (not shown) that may slide and rotate within respect to the engagement tips 12 in order to allow the tip members 12 move and provide the different functionalities of the tool 10 .
[0023] Opposite the tip members 12 , a pair of gripping handles 26 are each movably, and preferably pivotally connected to the central member 24 by pivot pins 28 or other suitable connectors. Alternatively, similar to the tip members 12 , the tool 10 can include only a single movable handle 26 , with the handle 26 movable with respect to a stationary member (not shown) to provide the compression or distraction function.
[0024] The handles 26 are each formed of a generally rigid material, such as a metal, and preferably are formed with a shape that is conducive to easy gripping of the handles 26 by an individual. Opposite the central member 24 , the gripping handles 26 are connected to one another by a locking mechanism 30 . The locking mechanism 30 includes a slide or rod 32 connected, preferably pivotally, at one end to one of the gripping handles 26 , and slidably received within a bore 34 disposed in the opposite handle 26 . The rod 32 includes a stop surface 35 opposite the end of the rod 32 connected to one of the handles 26 . The stop surface 35 has a diameter greater than the diameter of the bore 34 , such that the stop surface 35 can engage the periphery of the handle 26 around the bore 34 to maintain the rod 32 within the bore 34 .
[0025] Adjacent the bore 34 , the handle 26 having the bore 34 also includes a locking tab 36 pivotally connected to the end of the gripping handle 26 and including an aperture 38 therein through which the rod 32 extends. The rod 32 can slide through the aperture 38 formed within the tab 36 when the handles 26 are urged towards one another.
[0026] A spring 40 is disposed about the rod 32 between the locking tab 36 and the gripping handle 26 in which the bore 34 is formed. The spring 40 operates to urge the tab 36 away from the handle 26 to misalign the aperture 38 with the rod 32 , thereby frictionally engaging the tab 36 with the rod 32 in order to retain the gripping handles 26 in a stationary position. The positioning of the spring 40 enables the handles 26 to be moved toward one another without resistance from the tab 36 , as the movement of the handles 26 toward one another opposes the bias of the spring 40 . However, when the handles 26 are released, the spring 40 pushes the tab 36 into the frictional engagement with the rod 32 , effectively locking the handles 26 in the current position.
[0027] To disengage the locking mechanism 30 , the tab 36 is moved towards the handle 26 to which it is secured against the bias of the spring 40 to disengage the tab 36 from the rod 32 . This allows the handle 26 and tab 36 , along with the spring 40 , to slide along the rod 32 and move towards or away from the opposed gripping handle 26 to which the rod 32 is pivotally secured. With the locking mechanism 30 , it is capable to engage the gripping handles 26 in a stationary position with regard to one another at any relative position by allowing the tab 36 to engage the rod 32 at an infinite number of locations along the rod 32 .
[0028] Also, the design of the locking mechanism 30 does not have any sharp edges, teeth or ridges, as in prior art distractors and compressors, such that the mechanism 30 is less likely to become damaged even during regular usage, and is less likely to damage the gloves worn by an individual utilizing the tool 10 . Preferably, the handle 26 to which the tab 36 is attached includes an inwardly extending flange 39 positioned generally parallel to the rod 32 . The tab 36 is secured to the flange 39 adjacent the innermost end of the flange 39 to give the tab 36 a significant range of motion in either direction with respect to the rod 32 . Also, the presence of the flange 39 functions as a guard to the tab 36 , such that inadvertent contact with the flange 39 or rod 32 will not be able to disengage the tab 36 from the rod 32 , maintaining the locked position of the handles 26 .
[0029] Referring now to FIGS. 1-8 , in order to mechanically translate the movement of the gripping handles 26 into corresponding compressive or distractive lateral movement of the tip members 12 , a central shaft 42 is positioned within and extends through a central channel 44 defined in the central member 24 . A first end 46 of the shaft 42 is positioned between and equidistant from each of the tip of members 12 . The shaft 42 also includes a pair of sets of pivot members 48 each pivotally connected at one end to the first end 46 of the shaft 42 via pivot pins 50 and 52 engaged with the first end 46 , and at the opposite ends to the tip members 12 via pivot pins 54 - 60 , though other suitable connections (e.g., sliding connections) can be made between the pivot members 48 and the shaft 42 and tip members 12 . In this configuration, as the shaft 42 slides through the channel 44 in the central member 24 in a direction towards the tip members 12 , the shaft 42 operates to urge the tip members 12 always from one another in a distractive moment as a result of the engagement of the tip members 12 with the shaft 42 via the sets of pivot members 48 . Conversely, as the shaft 42 slides through the channel in the central member 24 in a direction away from the tip members 12 , the shaft 24 pulls the sets of pivot members 48 and the tip members 12 towards one another in a compressive movement.
[0030] Between the gripping handles 26 , the central member 24 includes a guide sleeve 62 secured to the central member 24 around the channel 44 and through which the second end 64 of the shaft 42 extends. The sleeve 62 ensures that the shaft 42 moves in a strictly linear fashion with regard to the remainder of the tool 10 .
[0031] Disposed on the second end 64 of the shaft 42 is an operational shifting member or saddle 66 . The saddle 66 includes a central bore 68 through which the second end 64 of the shaft 42 extends. The saddle 66 is maintained in engagement with the shaft 42 by the sleeve 62 at one end, and by an end cap 70 secured to the second end 64 of the shaft 42 opposite the sleeve 62 . Additionally, the saddle 66 is urged away from the central member 24 by a spring 69 disposed within the sleeve 62 and engaged at one end by a ring 69 a secured to and extending outwardly from the saddle 66 partially into the sleeve 62 , and by the central member 24 at the opposite end. The spring 69 functions to move the saddle 66 along the shaft 42 away from the central member 24 to move the tool 10 to the position shown in either FIGS. 1 and 2 , or FIGS. 5 and 6 when the locking mechanism 30 is disengaged. The saddle 66 is also pivotally connected by pivot pins 71 or any other suitable connection, to one end of a pair of pivot arms 72 that are each pivotally connected at the opposite end to the gripping members 26 at a location spaced from the rod 32 by pivot pins 73 .
[0032] The saddle 66 also includes a locking device 74 disposed within the body of the saddle 66 that at least partially obscures the central bore 68 extending through the saddle 66 . The locking device 74 is selectively engageable with one of a number of notches 76 located in the second and 64 of the shaft 42 between the sleeve 62 and the end cap 70 . These notches 76 are disposed on opposite sides of the center point 77 of the second end 64 of the shaft 42 , such that the pivot arms 72 are either angled towards or away from the central member 24 when the saddle 66 and locking mechanism 74 engaged with these notches 76 . When these saddle 66 is engaged with a notch 76 closer to the central member 24 , as illustrated in the FIG. 1 , the compression of the gripping handles 26 towards one another causes the shaft 24 to slide through the central number 24 towards the tip members 12 , causing the tip members 12 to move outwardly in a corresponding distraction movement. Conversely, when the saddle 66 is engaged with notch 76 closer to the end cap 70 , as shown in FIG. 2 , the movement of the handle members 26 towards one another slides the central shaft 42 all way from the central number 24 , drawing the tip members 12 towards one another in a compressive movement.
[0033] With the construction of the tool 10 according to the present invention, the amount of force required to move the handle members 26 towards one another is greatly lessened, such that the structural components of the tool 26 including the handle members 26 undergo less stress during operation of the tool 10 . Consequently, the materials utilized in the construction of the tool 10 can be selected from materials that are more lightweight than prior art compression tools and distraction tools.
[0034] Additionally, as a result of the construction of the tool 10 with the central shaft 42 and the saddle 66 , the stroke and leverage of the tool 10 can be altered by varying the position of the saddle 66 with regard to the shaft 42 in each mode of operation of the tool 10 . This allows the power generated by the operation of the tool 10 to be varied by positioning the saddle 66 at the proper or desired location along the shaft 42 . Further, the operation of the tool 10 in either mode is not strictly linear, such that less force is required to move the handles 26 near the end of the stoke of the tool 10 .
[0035] Various other embodiments of the present invention are contemplated as being within the scope of the filed claims particularly pointing out and distinctly claiming the subject matter regarded as the invention. | A combined compressor and distractor tool is provided that includes a mechanism capable of switching the mode of operation of the tool from a compression tool to a distraction tool. The tool includes engagement tips and handles at opposed ends of the tool that are pivotally connected to a central shaft. A saddle is slidably mounted on the shaft between and pivotally connected to the handles. When the saddle is engaged with the shaft in a before center position, squeezing the handles results the movement of the shaft forwardly to operate the engagement tips as a distractor. However, when the saddle is engaged with the shaft in a past, or over center position, squeezing the handles results the movement of the shaft rearwardly to operate the engagement tips as a compressor. | 0 |
BACKGROUND
1. Field of the Invention
This invention relates to hip stem prothesis apparatus and, more particularly, to a novel bone milling guide apparatus and method for the precision milling of a socket into the medullary cavity of the proximal femur of a patient, the socket thereby being prepared to receive a hip stem in a close-fitting relationship.
2. The Prior Art
Total hip replacement is one of the most remarkable advances in orthopedic surgery of this century. Since the first total hip joint replacement in 1962, significant advances have been made in both implant design and surgical technique. These improved devices and procedures offer new hope for patients crippled by degenerative arthritis, rheumatoid arthritis, or significant trauma to the hip. Diseases such as rheumatoid or osteo-arthritis generally result in degradation of the cartilage lining the acetabulum so that the ball of the femur rubs against the ilium. This rubbing action causes pain and further degradation of the remaining cartilage. Bone erosion causes the affected bones to attempt to compensate by reshaping, thus resulting in a misshapen joint which may eventually cease to function altogether.
Total joint replacement can provide not only marked resolution of pain but significant functional improvement. Currently, approximately 250,000 successful total joint replacements are performed each year in the United States alone so that the replacement of a hip joint with an artificial implant or prosthetic device is now a routinely practiced surgical procedure. The long-term success rate following total hip replacement is excellent. It is estimated that over 90% of patients who have had total joint replacement are functioning well 12 years after surgery.
A conventional hip prosthesis consists of an artificial femur head or ball mounted on the neck end of a stem with the ball being received in a prosthetic acetabular socket affixed to the ilium. The proximal end of the femur is removed and the stem is anchored in the medullary bone cavity. Despite overall excellent results, problems may infrequently develop following total joint replacement. The major potential complication of total joint replacement is infection. Pain following total joint replacement may also be due to mechanical loosening or breakage of the implant resulting in excessive motion between the prosthesis and the underlying bone. In relatively rare instances, a second, total joint replacement or revision may be required. It is estimated that approximately five percent of all total joint replacements performed today are revisions of previous procedures.
One of the major problems encountered during joint-replacement surgery is the need to securely anchor the hip stem portion of the prosthesis in the medullary bone cavity. Numerous attempts have been made to solve this particularly vexing problem. Early procedures involved reaming most of the cancellous bone from the proximal end of the medullary canal followed by packing the resulting cavity surrounding the prosthetic hip stem with bone cement so as to assure fixation between the hip stem and the surrounding cortical bone. Bone cement was necessitated because the metaphyseal geometry does not necessarily have any relationship to diaphyseal geometry, and it was found to be virtually impossible to predetermine the precise configuration for the prosthetic device. Accordingly, the customary practice was to use the cement material to achieve fixation by using it as a filler between the hip stem and the adjacent cortical bone. Unfortunately, revision is also rendered considerably more difficult by the presence of bone cement.
Clinical experience by a noted orthopedic surgeon over the last decade has demonstrated that, in the short term, cemented arthroplasties are more forgiving than those designed for biologic fixation. For example, it was found that it was rare for a patient with a cemented arthroplasty to experience clinical symptoms of fixation failure within the first few postoperative years. In contrast, a technically poor insertion of a porous-coated implant often results in fixation failure from the very start, with patient dissatisfaction as soon as weight bearing is allowed.
A more suitable alternative that has evolved is that of a noncemented total hip replacement wherein the prosthesis is implanted in the absence of a cement. The potential for adequate bone ingrowth to create an enduring cementless implant fixation can be realized only if stable fixation is achieved from the start, particularly since fixation through bone ingrowth succeeds or fails within the first several months after implantation. The most important prerequisite for secure fixation and better physiological stress transfer between implant and osseous tissue is initial mechanical stability. Micromotion between the implant and the surrounding osseous tissue into which it is inserted must be minimal during the time when the intramedullary fracture callus adjacent the implant is differentiating into osseous tissue and maturing. This initial mechanical stability can only be achieved with careful preoperative planning, meticulous surgical technique and a wide selection of incrementally sized hip stem components.
The fundamental problem is still that of the range of anatomical variations encountered in the femur. Basically, the medullary cavity of the femur is in the shape of an inverted, triangular pyramid at the top and a rod at the bottom. The first problem during preparation of the medullary cavity is to match the diaphysis which can be done by simple reaming to define the size of the stem. The second problem is to match the proximal end of the stem to the cortical bone. One approach is to provide the stem with a size range of sleeves which can be mounted to the stem in a locking relationship using a conventional Morse taper. Not only does the Morse taper allow one to use a preselected sleeve size, but it also accommodates placement of the triangular portion of the sleeve at a preselected angle to the neck of the stem.
From the foregoing it can be readily seen that the preparation of the proximal end of the femur to receive the proximal end of the hip stem is the major challenge. One bone milling device is disclosed by Frey et al (U.S. Pat. No. 4,777,942) and includes a milling instrument having a caliper that is inserted into the medullary cavity. A spindle is linked to the caliper at an angle and carries a milling cutter as well as a guide shoe at its distal end. The guide shoe slides within a guideway on the distal end of the caliper. The instrument guides the milling cutter to cut a circular arc corresponding to the boundary line between the spongiosa and cortical tissue in the region of the calcar arc.
Forte (U.S. Pat. No. 4,306,550) discloses a combination of tools and methods used to prepare a socket in a femur for receiving a femoral prosthesis. A rasp is used to form a socket in the femur. A cutter is journaled to the rasp prior to its removal and is rotated to machine the surface of the calcar surrounding the socket.
Experience has shown that these prior art devices are complex and require extensive experience before they can be used with any suitable degree of accuracy. Further, even experienced surgeons must rely heavily on personal expertise to accommodate for the fact that neither of these prior art devices accurately control the preparation of the medullary cavity or socket with a suitable degree of precision.
In view of the foregoing it would be an advancement in the art to provide a bone milling guide to enable the surgeon to easily and accurately mill the proximal end of a femur to receive a hip stem prosthesis. It would also be an advancement in the art to provide a bone milling guide that is simple to use and is mountable in the socket prepared to receive the distal stem of the prosthesis. Such a novel apparatus and method is disclosed and claimed herein.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
This invention is a bone milling template that is used to enable the surgeon to accurately and easily guide a bone miller in the preparation of the intramedullary cavity in the proximal end of the femur to receive the proximal end of a hip stem in close-fitting relationship. The template is demountably attached to a probe that is inserted into the bore created to receive the distal stem. The template accurately controls the movement of the bone miller in cutting a socket to receive the proximal end of the hip stem.
It is, therefore, a primary object of this invention to provide improvements in cutting control devices for controlling the cutting of bone to receive a hip stem.
Another object of this invention is to provide improvements in the method of preparing the proximal end of a femur to receive a hip stem.
Another object of this invention is to provide a template apparatus for accurately guiding a bone miller in cutting the proximal end of a femur to receive a hip stem.
Another object of this invention is to provide a template for a calcar miller wherein the position of the template is fixed by being partially inserted into a truncated cavity created in the intramedullary canal.
These and other objects and features of the present invention will become more readily apparent from the following description in which preferred and other embodiments of the invention have been set forth in conjunction with the accompanying drawing and appended claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded, perspective view of the novel bone milling guide of this invention shown in the presence of a distal stem guide;
FIG. 2 is a plan view of the bone milling guide;
FIG. 3 is a side elevation of the bone milling guide;
FIG. 4 is a cross sectional view of a proximal end of a femur shown in the process being drilled to receive a distal stem;
FIG. 5 is a cross sectional view of the proximal end of the femur of FIG. 4 being reamed at its proximal end to receive the truncated portion of the bone milling guide;
FIG. 6 is a cross sectional view of the proximal end of the femur of FIG. 5 with the bone milling guide in place in the medullary cavity and in the presence of a bone miller; and
FIG. 7 is a cross sectional view of the proximal end of the femur of FIG. 6 showing the intramedullary cavity prepared through the use of the bone milling guide of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is best understood by the following description and appended claims with reference to the drawing wherein like parts are designated by like numerals throughout.
General Discussion
Bone consists of two basic types of tissue: hard or compact bone which is dense in texture, and soft or cancellous bone which consists of fibers and lamellae joined together to form a reticular network. The hard bone tissue is generally referred to as the cortical bone and constitutes the outer wall of the bone where it provides most of the overall strength of the bone. The thickness of the cortical bone varies at different positions along the length of the bone with the greatest thickness along the midpoint where the cross sectional area of the bone is the smallest. The cortical bone is thinner adjacent the ends where the bone flares outwardly to support the particular joint mechanism.
Where present, cancellous bone forms the inner core of the bone with the major portions of cancellous bone being found adjacent the ends of the bone where the cross sectional area is the greatest and, correspondingly, where the cortical bone is the thinnest. It is currently believed that the cancellous bone in these regions contributes to the overall strength of the bone by transferring a portion of the applied stresses from the thin sections of cortical bone to the relatively large areas of thicker cortical bone located closer to the midsection of the bone. In these regions of stress transfer, the fibers making up the cancellous bone appear to have a regular equipotential-like arrangement wherein fibers intersect the internal surface of the cortical bone at spaced intervals of approximately one to two millimeters. It is believed that this arrangement, at least in part, is responsible for the efficient transfer of applied stress from one part of the cortical bone to another.
The proper implantation of a prosthesis into an intramedullary cavity created in the cancellous bone involves very close tolerances in order to achieve good initial fit. Good initial fit is important because of its direct correlation to a smoother postoperative course involving less adaptive bone remodeling and earlier weight bearing. One study underscored the importance of a quality initial fit wherein it was found to be the most significant factor influencing outcome. Surprisingly, the quality of the initial fit was even more important than any of bone quality, diagnosis, age, and sex. These latter factors were found to be of lesser significance in predicting results. The goal of a good fit is to optimally fill the intertrochanteric area in the coronal plane. Clearly, a limited degree of compromise is required between the shape of the implant versus the intertrochanteric area by the simple fact of the wide variations found among femurs. The reasonable alternative, therefore, is to accurately shape the intramedullary cavity so as to receive the implant in a precision, scratch-fit relationship.
Detailed Description
Referring now to FIGS. 1-3, the novel bone milling guide of this invention is shown generally at 10 and includes a template 12 extending from an upper edge of a hollow body 14. Hollow body 14 is configured with a vertical sidewall 13 formed with an external profile having a downwardly oriented taper as a portion of a truncated, right circular cone, the external profile of which closely approximate the shoulder region of the hip stem prosthesis (not shown) to be inserted in the intramedullary cavity 82 (FIG. 7). One side of hollow body 14 opposite vertical sidewall 13 is open as an opening 18 to expose the adjacent cancellous bone 63 (FIG. 6) to bone miller 50 (FIG. 6) as will be described more fully hereinafter. Interiorly, hollow body 14 has a coaxial cavity 15 configured as a downwardly tapered cavity terminating in a socket 16. The basal end of hollow body 14 terminates in a short, cylindrical base 19 which serves as a mounting surface for a guide 30 releasably mounted to hollow body 14.
Template 12 extends outwardly from one side of the upper edge of hollow body 14 and is configured with a generally tapered, lozenge shape as shown in the plan view of FIG. 2. Template 12 includes an inwardly sloped inner face 20, the slope of which corresponds to an imaginary line 11 (FIG. 3) extending between inner face 20 and a rim 17 forming a face of socket 16 located coaxially in the base of hollow body 14. Template 12 extends outwardly and orthogonally to the axis of hollow body 14.
The inner face of template 12 is provided with an inwardly-sloped surface 20, the slope of which corresponds to an imaginary surface extending upwardly from a rim 17 of socket 16. The region defined by the imaginary surface extending between sloped surface 20 and rim 17 is designated by cutout region 18. Cutout region 18 represents the portion of cancellous bone 63 (FIGS. 4-6) to be removed by a bone miller 50 (FIG. 5) as will be discussed more fully hereinafter.
Guide 30 has a threaded, coaxial boss 32 at a proximal end and is configured to be threadedly engaged to hollow body 14 at base 19 and includes a rounded tip 34 at a distal end. Guide 30 is adapted to be releasably mounted to base 19 in a coaxial relationship with hollow body 14 by threaded boss 32 being threadedly engaged in a corresponding threaded bore 24. Guide 30 is configured to be inserted into a hole 65 (FIGS. 4-6) drilled into the intramedullary canal 66 of bone 60. Guide 30 has a smooth, cylindrical profile and is designed to slidingly engage the cancellous bone 63 forming the sidewall of bore 65 drilled therein.
Referring now to FIG. 4, a bone 60 is shown schematically and in a cross sectional view with the ball portion (not shown) removed leaving a major portion of the greater trochanter 68 intact. The calcar region 62 is shown cut horizontally across the end of bone 60 which includes both cortical bone 64 and cancellous bone 63. Hole 65 is drilled into intramedullary canal 66 according to conventional techniques using a drill 70. The diameter and length of drill 70 are selected by the surgeon (not shown) so as to provide the appropriate size of hole 65 to receive the guide 30 (FIGS. 1 and 6) and pilot 74 (FIG. 5) prior to insertion of the distal stem of a hip stem prosthesis (not shown).
Referring now to FIG. 5, hole 65 is shown as having been completed in cancellous bone 63 and a reamer 72 has been used to cut into cancellous bone 63 to prepare a cavity 80 in the same for insertion of bone milling guide 10 (FIGS. 1-3 and 6) as will be discussed in reference to FIG. 6. Reamer 72 is a conventional reamer having a frustoconical profile and is adapted to have a distal pilot 74 releasably affixed thereto. The external profile of reamer 72 is configured to conform to the external profile of hollow body 14 (FIGS. 1-3 and 6). Distal pilot 74 is inserted into hole 65 so as to control reamer 72 in reaming the frustoconical portion of cancellous bone 63. Distal pilot 74 is essentially identical to guide 30.
Referring now to FIG. 6, bone milling guide 10 has been inserted into a cavity 80 created by reamer 72 (FIG. 5) in cancellous bone 63. Bone milling guide 10 is directed into cavity 80 by guide 30 being releasably secured to bone milling guide 10 and inserted into hole 65. Template 12 is held an incremental distance above the cortical bone 64 surrounding calcar region 62. Thus secured, bone milling guide 10 is now ready to receive therein bone miller 50. Bone miller 50 has a rounded tip 52, a milling surface 54, and an upper, guide follower 56.
The cutout region 18 shown in FIG. 1 is now seen as a segment of cancellous bone 63 residing between cavity 80 and a dashed line 11 extending between rim 17 and sloped surface 20 on template 12. Cutout region 18 represents the segment of cancellous bone 63 to be removed by a bone miller 50. Bone miller 50 is inserted downwardly into bone milling guide 10 along the axis of cavity 15 until rounded tip 52 is received in socket 16. Bone miller 50 is then moved in an arcuate path with guide follower 56 following the profile defined by sloped surface 20 of template 12 while rounded tip 52 is held in socket 16. The movement of bone miller 50 in this arcuate path allows milling surface 54 to remove all of cancellous bone 63 in cutout region 18 providing cavity 80 with an enlarged cavity 82 as defined by dashed line 19 and also as shown in FIG. 7.
Referring now to FIG. 7, bone milling guide 10 and guide 30 have been removed from bone 60 leaving a precision machined cavity 82, which in combination with hole 65, is prepared to accurately receive the preselected hip stem (not shown) in snug-fitting relationship. Advantageously, hole 65 and cavity 82 are prepared quickly and accurately in comparison with the prior art techniques and, more importantly, with a far superior degree of precision.
The Method
Referring now to all of FIGS. 1-7, the procedure for using bone milling guide 10 is described. Once bone 60 has been surgically exposed, the ball portion thereof (not shown) is removed according to conventional surgical techniques leaving intact as much of the greater trochanter 68 as possible. Importantly, the calcar surface 62 is prepared so as to receive thereon, the abutment surface of the hip stem prosthesis (not shown). Drill 70 is directed along the axis of the intramedullary canal 66 leaving hole 65 therein. Advantageously, drill 70 removes the cancellous bone 63 to preclude fragments thereof from becoming compacted in the bottom of hole 65.
Guide 74 is mounted on the basal end of reamer 72 and directed into hole 65. The diameter of guide 74 is incrementally smaller than the diameter of hole 65 so as to allow hole 65 to telescopically receive guide 74 in rotational relationship therewith. Guide 74 is used to directionally control the downward traverse of reamer 72 into cancellous bone 63 thereby providing an accurately machined, frustoconical cavity 80 in cancellous bone 63. The cancellous bone machined from cavity 80 is also removed by reamer 72 and not allowed to become compacted in the bottom of hole 65.
Hollow body 14 of bone milling guide 10 is dimensionally configured to be received in cavity 80 in snug-fitting relationship. Prior to inserting bone milling guide 10 into cavity 80, guide 30 is mounted thereto to provide alignment of bone milling guide 10 relative to bone 60. Template 12 is held an incremental distance above calcar surface 62 and the orientation of bone milling guide 10 relative to bone 60 is adjusted according to the surgical technique employed.
Bone miller 50 is then directed coaxially into hollow body 14 until rounded tip 52 is received in socket 16. Guide surface 56 is brought into contact with sloped surface 20 along the inner face of template 12 to thereby cause bone miller 50 to remove the underlying portion of cancellous bone 63 to enlarge a side portion of cavity 80 into cavity 82. The resulting cavity 82 has thereby been machined with precision. The resulting fragments (not shown) of cancellous bone 63 are removed to prevent them from becoming compacted in hole 65. With the completion of cavity 82, bone milling guide 10 along with distal guide 30 are removed from bone 60. Any residual fragments of cancellous bone 63 are also removed from cavity 82 and hole 65 prior to the insertion of the hip stem prosthesis (not shown). Importantly, the novel bone milling guide 10 apparatus and method of this invention readily enables the surgeon (not shown) to accurately and relatively quickly prepare cavity 82 to receive the appropriate hip stem prosthesis (not shown) in snug-fitting relationship. Further, this snug-fitting relationship is achieved in the absence of fragments of cancellous bone 63 becoming compacted in hole 65 as is the case when conventional reaming techniques are employed. Advantageously, the sizes of drill 70, reamer 72, and the contour of the cut defined by template 12 through the use of bone miller 50 are all selectively predetermined and coordinated with corresponding elements of the hip stem prosthesis (not shown) to provide an accurately machined cavity 82 for receiving therein the hip stem prosthesis (not shown) in a snug, close-fitting relationship. Such a fit assures a more secure ingrowth of bone earlier and also a much earlier weightbearing capability.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A bone milling guide apparatus and method for preparing the proximal end of a femur to receive a hip stem prosthesis in snug-fitting relationship. The ball portion of the femur is removed using conventional surgical techniques to expose the underlying cancellous bone. An axial bore is drilled in the intramedullary canal to receive the distal portion of the hip stem prosthesis. The proximal end of the axial bore is reamed to form a tapered recess which is dimensionally configured to receive a portion of the external surface of the proximal end of the hip stem prosthesis. A tapered, hollow body is inserted into the tapered recess and supports a U-shaped template extending outwardly therefrom. Each arm of the U-shaped template is affixed to the tapered, hollow body on each side of a longitudinal slot in the side of the tapered, hollow body. A bone miller is inserted coaxially into the hollow body and tilted angularly through the longitudinal slot to remove cancellous bone in the region defined by the hollow body and the template. | 0 |
PRIOR APPLICATION
This application is a U.S. national phase application based on Swedish Patent Application No. 0203652-3, filed Dec. 10, 2002.
The invention relates to a juggling torch.
BACKGROUND AND SUMMARY OF INVENTION
In the field of entertainment artists sometimes work with a juggling torch such as a juggling club or the like that has a wick in which fuel is absorbed so that fuel is lit and permitted to burn while the torch is handled wherein the artist's act is performed in a room that is dark or has moderate lighting. The term juggling torch is intended to include all types of torches or devices that have a wick into which a burning fuel is absorbed and that is handled by the artist. Examples of such torches are for example a juggling torch, a “poi”, a “devil stick”, a rod or a “swing” torch. Such torches have their own normal pattern throwing motion but can, in general, be thrown, fly in circles, be swung, be circulated etc.
A previously known practical example of such a juggling torch include a juggling club that includes a bar that in a middle area of its length has a heavy body and that has a handle at one of its end and has at its other end a diameter of about 2.5 cm, carry a wick of a fiber material such as Kevlar and/or cotton, wherein the wick has the shape of a band that is wound about the end of the bar along a axial distance of 6-7 cm, wherein the wick has a radial thickness of about 1 cm. The wick is dipped in fuel, such as lamp oil, Kerosene or n-paraffin. The amount of fuel that can be absorbed in such wick has a relatively short burning time. It is in practice difficult to achieve a longer burning time with the help of a bigger wick.
One object of the invention is to design a juggling torch that provides a substantially longer burning time.
The object is achieved with the invention.
The invention is defined in the appended independent claim.
The design variations of the invention are defined in the appended dependent claims.
An important feature of the invention is that the juggling torch includes a container for fuel and that the container is in fuel communication with the wick via one or many channels. Preferably, the container is arranged in the part of the club, one which the wick is arranged, so that a juggling motion of the torch results in that the fuel in the container is conveyed through the channel to and into the wick. The wick permits air therethrough at least when the club is in relative rest so that air may be sucked in through the wick or between the wick and its support and in via the connection to the container, to eliminate the under-pressure that otherwise occurs in the container as a result of the removal of fuel from the container to the wick.
The channel or the channels can have the shape of one or many radial bores at the bottom part of the container so that the channels exit at the lengthwise middle area of the wick.
In one embodiment of the invention the torch can be built from an elongate section of a tube that at its one end has a tight lid for fuel addition purposes. In the other end of the tube, at a distance from its end that corresponds to half of the length of the wick, is a tight bottom that defines a bottom of a container between the bottom and the lid. The channels are formed by the bores through the wall of the tube in the container adjacent of its bottom. The bores that each has a diameter of 1 mm is in practice suitable for a juggling torch that has a wick of 7 cm length and a thickness of 1 cm when the outer diameter of the tube is 22 mm.
A mid-portion of the length of the tube section may be surrounded by a body attached thereto that is rotation symmetrical to the axis of the tube and that suitably has a bore going therethrough that corresponds to the outer diameter of the tube. At the short end, the tube is surrounded by a graspable sleeve.
As a result of the invention the torch can have a burning time that is ten times longer than the burning time of a torch that solely relies on saturating the wick with fuel.
The flow resistance that the channels must provide for the fuel flow to the wick must naturally be adjusted to the characteristics of the wick and the fuel so that the fuel that during the juggling is conveyed from the container through the channels into the wick corresponds to the fuel flow that is burning at the wick.
Based on a conventional wick of Kevlar/cotton yarn, that has an inner diameter of 22 mm, an outer diameter of 42 mm and an axial length of about 65 mm, it has been shown that the juggling torch, that is built from an aluminum tube with a length of 500 mm and a 22 mm diameter satisfy this requirement when two channels extend through the tubing wall (wall thickness 1 mm) and has a diameter of about 1 mm and the fuel has the mentioned characteristics.
The invention is described below with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows an axial section through the juggling torch
FIG. 2 schematically shows a section along the line II-II in FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 shows a juggling torch that is based on a length section of an AL-tube with an outer diameter of 22 mm and a wall thickness of 1 mm. At the one end 11 of the tube 1 a sealing plug 2 is shown that is removable but sealingly inserted into the end of the tube 1 . At the other end 12 of the tube 1 there is a circular cylindrical wick applied around the circumference of the tube 1 and that extends to the end of the tube 1 . The wick has a length of 6-7 cm and a radial thickness of 1 cm. The wick 3 has a band of Kevlar and/or cotton that is wound about the tube 1 to form the wick 3 .
A handle sleeve 4 is mounted on the tube 1 adjacent to the end 11 . A club 5 , that is rotation symmetrical to the axis of the tube 1 , is mounted on the tube 1 and that forms an inert body that defines a suitable position for the center of gravity of the torch along the tube 1 . The inner diameter of the club 5 corresponds to the outer diameter of the tube 1 .
At the other end 12 of the tube is a bottom wall 14 that shields the inner cross-section of the tube 1 . The tube 1 forms, together with the bottom 14 and the plug 2 a container for fuel, such as n-paraffin. In the container, adjacent to the bottom wall 14 , are two diametrically opposite bores 15 that have a diameter of 1 mm. The bores 15 form channels, through which fuel from the container can flow to the wick 3 . The wick 3 permits air to flow therethrough and can let air in through the bores 15 in the container if an under-pressure is formed in the container relative the surroundings. The torch is usually handled in such a way that its motion brings fuel to move in the direction toward the exit of the container so that fuel is driven out through the channel or channels to the wick. The container is thus arranged so that the fuel is given such a motion or drive towards the channel and the wick during the handling of the juggling torch. Commonly, the juggling torch, in general, is provided a motion during the handling of the torch so that the fuel is given the indicated motion.
During juggling of the torch the fuel can thus be given an inertia force in the direction toward the bottom 14 and strives to be pressed out through the bores 15 to the wick 3 . When the wick 3 is moisturized by fuel and is lit, a flame is established that during the juggling act represents fuel consumption. This fuel consumption is to be balanced by a corresponding fuel flow through the bores 15 and the wick 3 .
During the sudden interruption of the throwing motion of the torch air can be sucked in through the wick into the container 7 for pressure compensation of the container.
The channels and/or the wick define a flow resistance that at least partially regulates the fuel flow between the container and the burning flame wherein the fuel flow substantially corresponds to the fuel consumption of the flame so that the flame can be maintained without the risk of fuel (burning) leaving the wick during the juggling handling of the torch. | The juggling torch has a torch body ( 1 ) with a wick ( 3 ) for fuel that is absorbed by the wick ( 3 ) and a fuel container ( 7 ) that is connected to the wick ( 3 ) via one or many channels ( 15 ). | 0 |
TECHNICAL FIELD
The invention relates to a unique handle structure, and more particularly to a handle structure which provides the user with a comfortable, natural grip, while maintaining the orientation of the user's wrist in a neutral or flexed position during the performance of gripping, pulling, or lifting movements.
BACKGROUND ART
The handle of the present invention has many uses, as will be apparent hereinafter. The handle of the present invention is particularly well adapted for use with weight lifting and exercise equipment where the achievement of maximum grip is of utmost importance in achieving a beneficial workout. The purpose and benefits of the handle of the present invention are easily illustrated in the field of weight training because this activity requires that a neutral or slightly flexed grip is first achieved, and then continuously maintained to facilitate maximum weight and number of repetitions for the user to achieve the desired physiological results from the exercise routine. For this reason, and for purposes of an exemplary showing, the handle will primarily be described in its application to weight lifting and exercise equipment. It will be understood by one skilled in the art that this is not intended to be a limitation of the present invention other than as set forth in the claims hereinafter. The handle of the present invention can additionally be used in applications which require the user to grip and maintain continuous control of any attached device, such as in machine operation. The handle of the present invention can be used advantageously, for example, as a carrying handle for substantially any portable device intended for manual carrying.
The use of repetitive exercise and motions in weight lifting equipment training requires an individual to exercise specific muscle groups in an effort to tone, to increase the strength and to increase the size of the targeted muscle groups. There are currently many types of devices on the market which attempt to accomplish this goal, ranging from sophisticated multi-station machines to basic free weights, bar bells, and dumbbells. During any specific training period or routine, the user of these devices, whether the movement involves pulling or holding, must first achieve a grip which will provide to the user a mechanical advantage with respect to the device being manipulated. Most of these prior art devices, regardless of the degree of their complexity, are provided with handles which are basically cylindrical, having a substantially round cross-section, which fits into the palm of the user's hand.
In the use of weight lifting equipment, grip strength and grip endurance are essential in performing the necessary actions, especially pulling movements. In the field of weight training, a pulling movement is one in which the user pulls a weight toward his or her body. Another form of pulling movement is one in which the user pulls toward his or her body one or more handles attached to a weight by one or more cables. A seated cable row is a well known example of this. There are also numerous types of pull-down machines. Yet another pulling movement is the well-known chin-up or pull-up where the user pulls the body toward a fixed object from a dead hanging position.
Another important aspect of gripping is to distinguish between squeez-type gripping and hook-type gripping. The wrist in about 30 degrees to about 40 degrees of extension is in the optimal position for squeeze type gripping. However, in the applications to which the present invention is directed, a strong hook-type grip is more desirable than the classic squeeze grip. The mechanical advantage gained by using a hook-type grip overcomes any disadvantages normally believed to be associated with gripping in a partial state of flexion. The handles of the present invention are designed to maximize a very strong hook-type grip in contrast to the classical squeeze-type grip. The distinction here is the difference in the best grip for an axial or near axial load such as in pulling versus the power or squeeze grip used in grasping the handle of a hammer or the like.
As an example, in the above-mentioned exercise known as the seated cable row, the user is placed in a seated position on a flat surface with the feet extended to the front. Reaching forward towards the feet the user grasps a handle assembly providing two fixed bar-like cylindrical handle elements, one for each hand, which are approximately 8 inches apart and are perpendicular to the floor when held. The handle assembly is attached to one end of a cable which passes about a series of pulleys. The other end of the cable is attached to a selected weight. With the hands approximately 8 inches apart, palms facing each other, the user grasps the handles of the handle assembly by placing them in the palms of each hand. With the elbows slightly flexed and the back perpendicular to the floor, the user pulls back on the handle assembly until the hands touch the mid-section of the body. This results in a lifting of the weight attached to the cable. Thereafter, the user lowers the weight in a controlled manner, returning his body to the starting position in preparation for a sequential repetition of the same movement. This effort constitutes one "repetition" of the specific exercise. A non-stop series of such repetitions constitutes a "set".
It is typical for the user to attempt to perform four or more sets, comprising about 10 to 12 repetitions each, in a given exercise routine. The primary or target muscle group which benefits from this particular routine is the latissimus dorsi. The assisting muscles involved in this routine are the biceps (which enable the elbow to flex) and the forearm flexor muscles. Also involved are the flexor digitorum profundus and the flexor pollicis longus muscles, which enable the hands to grip the handle elements of the handle assembly. The flexor carpi radialis and the flexor carpi ulnaris, the primary wrist flexor muscles, maintain the wrists in a neutral or slightly flexed position. As the user progresses further into the exercise routine, the hand flexor muscles have a tendency to fatigue and the wrists begin to extend, thereby breaking the neutral plane. This results in the handle moving to the distal portion of the fingers, which puts the hand flexor muscles at a mechanical disadvantage, causing grip failure or the extending of excessive energy to maintain the user's grip. The handle of the present invention prevents fatigued wrist extension and maintains a powerful hook grip.
The present invention is based upon the discovery that a handle may be so shaped that it causes the user to maintain an optimum wrist position during gripping, pulling, and lifting movements. This enables the user to avoid premature grip/wrist fatigue while performing various types of work. The handle of the present invention, in its simplest form, comprises a substantially cylindrical grip portion with a substantially planar support portion extending tangentially from the grip portion. The angle formed between the support portion and the directional force should be from about 0 degrees to about 45 degrees, and preferably about 20 degrees to about 30 degrees, resulting in from about 0 degrees to about 45 degrees and preferably 20 degrees to about 30 degrees, of wrist flexion for optimal results. The user's hand grasps the handle in such a fashion that the four fingers of the hand curl around the grip portion and the palm lays flat against the support portion. The thumb may curl around the grip portion in a direction opposite the fingers, or the thumb may lie alongside the index finger, as will be explained hereinafter.
The support portion of the handle of the present invention can be applied to existing bars and handles already in use. The support portion can be affixed to a tubular member or to collars which can be mounted on existing bars or handles with a sliding fit and held thereon, in adjusted position, by set screws or other appropriate fastening means. In the same way, the palm supporting portion can be adjusted for optimum results to accommodate the particular application of the handle, as well as the physiological differences of the user's hand and arm structure. Thus, the handle can be adjusted to a fit which is comfortable to the user and provides the best mechanical advantage. In the case of a stirrup type handle where a cylindrical sleeve mounting the palm support portion cannot be slipped over the existing handle, the cylindrical sleeve can be made of two longitudinal halves which can be placed over the existing handle and joined together so as to be fixedly attached to the handle in adjusted position thereon.
As will be described hereinafter, the handle of the present invention can be provided in a more advanced design to fit the average hand. Handles of this sort will be made in left hand and right hand versions. In this embodiment, the flat portion which rests against the flat of the palm has a slight twist to add to the comfort of the handle.
With the handle of the present invention, the user can accomplish more work with less wrist/hand fatigue. As the user's forearm begins to fatigue and his hand begins to extend outward while the wrist begins to turn inward, the palm of the user's hand exerts pressure upon the support portion of the handle, reducing further hand extension. This keeps the grip portion of the handle between the proximal interphalangeal joint and the metacarpophalangeal joint, which is the position for the best hook grip possible for the user.
DISCLOSURE OF THE INVENTION
It is an object of the present invention to provide a handle that maintains the user's wrist in either a neutral or a slightly flexed position.
It is an object of the invention to provide a handle that can be adapted to be used with existing handles.
It is an object of the invention to provide adjustment capabilities with respect to the handle of the present invention to accommodate differences in user physiological structure and to accommodate different applications of the handle.
It is an object of the invention to provide a more ergonomic handle.
According to the invention, there is provided a handle which enables the user to achieve a comfortable, natural hook grip, while maintaining the user's wrist in a neutral or flexed position during the performance of gripping, pulling, or lifting movements, found, for example, in a repetitive exercise routine or an extended work routine. The handle facilitates grip strength and endurance.
In its simplest form, the handle comprises a grip portion from which a support surface extends tangentially. The user's palm is engaged by the support surface maintaining the user's wrist in a neutral or flexed position and preventing the hand and wrist from extending due to fatigue or slippage. The handle may be of such construction that it can serve as a handle for both the right hand and the left hand of the user. The handle may have a more sophisticated, ergonomic configuration requiring that it be specifically made in right hand and left hand versions. It is within the scope of the invention to provide a handle wherein the support surface is adjustable with respect to the grip portion to adjust for the application to which the handle is directed and for the physiological characteristics of the user's hand.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevational view of a human hand and wrist illustrating the normal maximal range of wrist extension for the average person.
FIG. 2 is a fragmentary elevational view of a human hand and wrist in the neutral position.
FIG. 3 is a fragmentary side elevational view of a human hand and wrist, illustrating the normal maximal range of wrist flexion for the average person.
FIG. 4 is a fragmentary side elevational view of a human hand and wrist gripping a handle, the hand and wrist being in an active stage of extension.
FIG. 5 is a fragmentary side elevational view of a hand and wrist, gripping a handle, the hand and wrist being in a neutral position.
FIG. 6 is a fragmentary side elevational view of a hand and wrist gripping a handle, the hand and wrist being in an active stage of flexion.
FIG. 7 is a fragmentary prospective view of the handle of a present invention.
FIG. 8 is a transverse cross-sectional view of the handle of FIG. 7.
FIG. 9 is an exploded perspective view of another embodiment of the handle of the present invention which may be adjustably affixed to an existing handle element.
FIG. 10 is an exploded cross-sectional view of the handle of FIG. 9.
FIG. 11 is a side elevational view of the left side of another embodiment of the handle of the present invention, made specifically for the right hand of the user.
FIG. 12 is a side elevational view of the right side of the handle of FIG. 11.
FIG. 13 is a rear elevational view of the handle of FIG. 11, as seen from the right side of FIG. 11.
FIG. 14 is a front elevational view of the handle of FIG. 11, as seen from the left side of FIG. 11.
FIG. 15 is a top plan view of the handle of FIG. 11.
FIG. 16 is a bottom view of the handle of FIG. 11.
FIG. 17 is a front elevational view illustrating a wrist and a left hand grasping a handle of the type shown in FIGS. 7 and 8.
FIG. 18 is a side elevational view of the wrist, hand and handle of FIG. 17.
FIG. 19 is a fragmentary top plan view of a mounting system by which the handle of the present invention may be attached to the end of a cable.
FIG. 20 is an elevational view of the structure of FIG. 19 as seen from the left of FIG. 19.
FIG. 21 is a perspective view illustrating a system by which a pair of handles of the present invention can be mounted to a cable for simultaneous grasping by the user's right and left hands.
FIGS. 22 through 25 are perspective views illustrating additional embodiments of the handle of the present invention.
FIG. 26 is a fragmentary elevational view illustrating the handle of the present invention in its application to a suitcase.
FIG. 27 is an elevational view of a handle assembly for a pull-down type exercise device, employing handles of the type described herein.
FIG. 28 is an end elevational view of the structure of FIG. 27, as seen from the right of that Figure.
DETAILED DESCRIPTION OF THE INVENTION
Reference is first made to FIGS. 1-3, wherein like parts have been given like index numerals. FIGS. 1-3 constitute a series of illustrations depicting the normal range of motion of the wrist for the average person. The range of motion and the manner in which it is depicted in FIGS. 1-3 are the accepted standard of the medical and sports communities.
FIG. 1 specifically depicts a left hand 1 and a wrist 2 in their maximum range of extension of about 70 degrees. FIG. 2 represents the left hand 1 and wrist 2 in a neutral or 0 degree position. FIG. 3 represents the left hand 1 and wrist 2 in their maximum range of flexion of about 80 degrees. FIGS. 1-3 illustrate the range of movement of the hand from substantially maximum extension to substantially maximum flexion so that the purpose of the handle of the present invention and the result of its use can be more fully understood. It will be further understood that the normal range of motion of the right wrist and hand of the average person will be essentially the same.
FIG. 4 shows the left hand 1 and wrist 2 wherein the left hand is grasping a round handle. The left hand is in the active state of extension. Arrow 3 of FIG. 4 depicts the direction of force or pull, away from hand 1. In FIG. 4, the metacarpophalangeal joint 4, the proximal interphalangeal joint 5, and the distal interphalangeal joint 6 are shown. FIG. 4 further illustrates the orientation of the wrist in an active state of extension. It will be noted that the direction of force 3 pulling away from the grasped hand 1 pulls through the distal interphalangeal joint 6. This is the optimal hand, wrist and arm position for a squeeze-type grip.
In FIG. 5, the line of force indicated by arrow 3 is pulling between the proximal and distal interphalangeal joint 5 and the wrist 2 is in a neutral position.
In FIG. 6, the line of force is pulling between the proximal interphalangeal joint 5 and the metacarpophalangeal joint 4, while the wrist is in an active state of flexion. This is the optimal hand, wrist and arm position for a hook-type grip to which the present invention is directed.
FIGS. 7 and 8 depict the handle of the present invention in its simplest form. The handle is generally indicated at 7 and comprises a grip portion 8 and a support portion 9. The grip portion 8 is a cylindrical or round bar-like portion substantially similar to the handles found on prior art exercising devices. The support portion 9 is a flat, planar, plate-like portion which extends tangentially from the peripheral surface of grip portion 8. In an exemplary embodiment, support portion 9 was about 4 inches wide and extended about 3 inches from grip portion 8.
Reference is now made to FIGS. 9 and 10. In these Figures a bar-like handle of circular cross-section is shown at 10. Mounted on handle 10 is a cylindrical sleeve 11 having a support member 12. Support member 12 is substantially identical to support portion 9 of FIGS. 7 and 8.
Cylindrical sleeve 11 has an internal diameter substantially equivalent to the external diameter of handle 10 so that sleeve 11 is mounted on handle 10 with a sliding fit. Sleeve 11 is provided with upper and lower sets of 3 evenly spaced, radial, threaded holes 13. The holes 13 are adapted to receive set screws 14, by which the sleeve and support member 11-12 can be affixed to handle 10 in any desired rotative position thereon. The embodiment of FIGS. 9 and 10 accomplish two purposes. First of all, it provides the handle of the present invention with an adjustable support member. Secondly, it illustrates a way in which a conventional handle 10 can be converted to a handle conforming to the teachings of the present invention.
It will be understood that a handle of the type shown in FIGS. 7 and 8 and a handle of the type shown in FIGS. 9 and 10 can serve as either a right or left handle.
FIGS. 11 through 16 illustrate a more advanced design in which the handle of the present invention is formed to fit the average hand. It will be understood that a handle of the type shown in FIGS. 11 through 16 must be made in right and left hand versions which are essentially mirror images of each other. The handle illustrated in FIGS. 11 through 16 constitutes a handle for the right hand and is generally indicated at 15. In FIG. 11, the support portion of the handle, equivalent to support portion 9 of FIG. 7, is indicated at 16. The top of the handle is indicated at 17 and the bottom of the handle is indicated at 18. Finger indentations are shown at 19, and a thumb indentation is shown at 20. Reference is now made to FIG. 12. It will be noted that throughout FIGS. 11 through 16, like parts have been given like index numerals. FIG. 12 illustrates the right side of the handle for the right hand. In FIG. 12, the surface of support portion 16 is curved as at 21 to fit the thenar eminence of the hand. FIG. 13 illustrates the handle 15 as viewed from the rear and FIG. 14 illustrates handle 15 as viewed from the front. FIG. 15 illustrates the handle viewed from the top, while FIG. 16 illustrates the handle viewed from the bottom.
Reference is now made to FIGS. 17 and 18. These Figures illustrate a left hand grasping a handle of the present invention. For purposes of an exemplary showing, the hand is illustrated as gripping the handle 7 of FIGS. 7 and 8. It will be understood that the handle of FIGS. 9 and 10 and the handle of FIGS. 11 through 16 would be grasped in an essentially identical manner.
In FIGS. 17 and 18, the arrow 21 indicates the direction of pull on the handle 7. The hand is shown in an active state of flexion. The thumb is shown wrapped around grip portion 8. The handle 7 may also be gripped in such a way that the thumb lies on the other side of grip portion 8. This type of grip is illustrated in FIG. 19 to be described hereinafter.
Whether the handle is to be attached to a fixed member, a cable, or a device to be lifted and/or carried, it is important that the attachment means is such that the support portion or support member is properly oriented to maintain the hand in an active state of flexion. The handle assembly 11-12 of FIGS. 9 and 10 could be attached to a chin-up bar or the like by means of the set screws 14. The set screws enable rotational adjustment of the handle assembly on the chin-up bar so that the support member 12 can accomplish its purpose.
FIGS. 19 and 20 illustrate an exemplary handle mounting system in an instance where the handle is to be mounted at the end of a flexible cable. Once again, FIGS. 19 and 20 illustrate the handle 7 of FIGS. 7 and 8 since the handle 7 represents the simplest embodiment of the present invention. It will be understood by one skilled in the art that the handle 15 of FIGS. 11 through 16, for example, could be mounted in the same way.
The handle mounting system is generally indicated at 22. The handle system comprises a first portion 22a which, at one end, is attached to the end of the grip portion 8 of handle 7. The other end of mounting system portion 22a terminates in a second portion 22b which lies in parallel spaced relationship to the grip portion 8 of handle 7, forwardly thereof. The mounting system portion 22b terminates in a third portion 22c which is located forwardly of the hand and extends in a direction perpendicular to mounting system portion 22b. The portion 22c terminates in a cable attachment ring 23. The direction of force on handle 7 and handle mounting system 22 is indicated by arrow 24 in FIG. 19. The force 24 tends to cause handle 7 to move in the direction of arrow 25. This assists in maintaining the active state of flexion. The greater the force at 24, the more handle 7 tends to shift in the direction of arrow 25.
FIG. 21 illustrates a mounting system, generally indicated at 26, for mounting two handles of the present invention to the end of a single cable. A pair of handles is used, for example, in the above-noted seated cable row exercise, where both hands are employed to pull simultaneously on a single cable. Again, for purposes of an exemplary showing, the handle 7 of FIGS. 7 and 8 is shown in both left and right hand orientations, the handles being identical. It will be understood that other embodiments of the handle of the present invention can be substituted for handle 7, such as the handle 15 of FIGS. 11 through 16. It will be remembered that handle 15 is made in left and right hand versions constituting mirror images of each other.
The dual handle mounting system 26 comprises a framework made up of a forward vertical member 26a. The member 26a has a transverse perforation 26b formed therein through which a cable ring 27 extends. From the upper end of member 26a a pair of laterally and rearwardly extending frame members 26c and 26d extend terminating in circular structures 26e and 26f, respectively. Similarly, at the lower end of frame member 26a an additional pair of frame members 26g and 26h extend laterally and rearwardly, terminating in circular members 26i and 26j. A pair of identical handles 7 are used, having their ends appropriately affixed to circular members 26e-26i, and 26f-26j. The two handles 7 are in parallel spaced relationship and are spaced from each other by an appropriate distance. Excellent results have been achieved when the spacing between handles 7 is about 8 inches.
In an instance where the handle structure of FIG. 21 is a pre-existing handle structure without the support portions 9, the support portions 9 could be added to the grip portions 8 in adjusted positions by providing the support portions 9 with split collars which can be joined together in any appropriate manner.
FIGS. 22 through 25 illustrate various modifications of the handle of the present invention. In FIG. 22, the handle is generally indicated at 29 wherein the grip portion comprises a rod-like member 30 of circular cross-section. To the grip portion there is affixed a support portion 31 to support the user's palm. The support portion 31 is a U-shaped portion, the legs of which terminate in cylindrical collars 32 and 33. The collars 32 and 33 are appropriately affixed to the grip portion 30 as by set screws 34, or other appropriate fastening means.
The handle of FIG. 23, generally indicated at 35 comprises a grip portion 36 identical to grip portion 30 to which collars 37 and 38, similar to collars 32 and 33 of FIG. 22, are attached by set screws 39, or the like. The support member 40 is similar to support member 31, having leg portions attached to the collars 37 and 38. That portion of support 40 extending between the support portion legs has a bend 41 formed therein to better fit the user's hand.
The embodiments of FIGS. 22 and 23 enable rotational adjustment of palm portions 31 and 40, respectively, by virtue of set screws 34 and 39. In both embodiments, an opening is defined between grip portions 30 and 36 and support portions 31 or 40, respectively. These openings enable the user to position his thumb in the manner shown in FIG. 18. Alternatively, the user may position his thumb in the manner shown in FIG. 19.
The collars 32 and 33 of FIG. 22 and the collars 37 and 38 of FIG. 23 could be made in two joinable halves for mounting on grip members which have pre-existing support means which preclude sliding of the collars onto the grips (see, for example, FIG. 21). Furthermore, the support members 31 and 40 could be attached tangentially to their respective collars, as is the support member 49 of FIG. 25 to be described hereinafter.
The handle embodiment illustrated FIG. 24 is generally indicated at 42 and comprises a bar-like grip 43 having a circular cross-section and a tangentially extending support 44. The support 44 may be affixed to grip 43 in any appropriate manner including flathead machine screws, welding, or the like, or the grip 43 and support 44 may constitute an integral, one-piece casting or molding. The support 44 has a large notch 44a formed therein enabling the user's thumb to more easily achieve a thumb lock position of the type shown in FIG. 17.
The handle of FIG. 25 is generally indicated at 45 and again is provided with a grip portion 46 in the form of a bar of circular cross-section. Adjustably mounted on grip 46 there is a collar 47 which is held in adjusted rotative position by set screws, two of which are shown at 48. The palm support portion of handle 45 is a T-shaped member 49, the stem of which extends tangentially from collar 47. The collar 47 could be a split collar as described with respect to FIGS. 22 and 23.
FIGS. 23 through 25 are but a sampling of the variations in which the handle of the present invention may be made. The primary features of the handle of the present invention comprise a grip portion and a palm support portion, the palm support portion being oriented in such a way as to maintain the user's arm and hand in a neutral position or an active state of flexion.
FIG. 26 illustrates the handle of the present invention applied to a suitcase. The handle is generally indicated at 50 and is basically of the type shown in FIGS. 7 and 8. To this end, the handle has a grip portion 51 and a palm support portion 52. At the ends of the grip portion, the handle is provided with a pair of downwardly extending legs (one of which is shown at 53 in FIG. 26). The leg 53 and its counterpart at the other end of grip 51 are affixed to the front face 54 of suitcase 55 in such a way that when a lifting force is applied to handle 50, the handle is rigid with respect to suitcase 55, but when a lifting force is no longer applied to the handle, the handle will pivot out of the way and against the face 54 of the suitcase. The handle 50 will allow the carrier to carry the suitcase with greater comfort and for longer periods of time with less wrist and hand fatigue.
Finally, FIGS. 27 and 28 illustrate a handle, generally indicated at 61 for use with a pull-down exercise device, incorporating the teachings of the present invention. The handle 61 comprises a central bar-like portion 62. From the center of bar 62 a short bar segment 63 extends upwardly. The free end of bar segment 63 terminates in a horizontal portion 64 on which is mounted a cable ring 65. At the ends of bar 62 a pair of handles 66 and 67 of the present invention are mounted. It will be noted that the handles 66 and 67 extend outwardly and slightly downwardly. The pulling force on the handle is indicated in both FIGS. 27 and 28 by arrows 68. Again it will be understood that the handles 66 and 67 will maintain the user's arm and hand in a neutral position or in an active state of flexion.
The present invention having been described in detail, it will be obvious to a person of ordinary skill in the art that a number of variations can be made thereto without departing from the spirit and scope of the invention. The invention should not be construed as being limited to the specific disclosed preferred embodiment or its variations illustrated herein, but rather should be construed as limited only by the claims appended hereto and all reasonable equivalents thereof. | A handle structure providing the user with a comfortable, natural, hook-type grip, maintaining the use's wrist in a neutral or flexed position during the performance of gripping, pulling, or lifting movements of a repetitive exercise routine or an extended work routine, to facilitate grip strength and endurance. The handle comprises a grip portion from which a fixed or adjustable support surface extends tangentially, the user's palm is engaged by the support surface preventing the hand and wrist from extending due to fatigue or slippage. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Some of the aspects of the methods and systems described herein have been described in
[0002] U.S. Provisional Application Nos. 61/780,408 entitled “Systems And Methods To Synchronize Data To A Mobile Device Based On A Device Usage Context”, filed Mar. 13, 2013; 61/781,252 entitled “Systems And Methods To Secure Short-Range Proximity Signals”, filed Mar. 14, 2013; 61/781,509 entitled “Systems And Methods For Securing And Locating Computing Devices”, filed Mar. 14, 2013; 61/779,931 entitled “Systems And Methods For Securing The Boot Process Of A Device Using Credentials Stored On An Authentication Token”, filed Mar. 13, 2013; 61/790,728 entitled “Systems And Methods For Enforcing Security In Mobile Computing”, filed Mar. 15, 2013; and U.S. Non-Provisional application Ser. No. 13/735,885 entitled “Systems and Methods for Enforcing Security in Mobile Computing”, filed Jan. 7, 2013, each of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0003] The present invention is in the technical field of communications security. More particularly, the present invention is in the technical field of policy enforcement related to administrative access in mobile communications devices in a manner that, among other things, provides significant improvements in energy efficiency.
SUMMARY OF THE INVENTION
[0004] The present invention includes a method for synchronizing data to a mobile device based on device usage context.
[0005] Modern mobile devices often store data that is synchronized with a remote system, such as a server. Because of its finite resources compared to the remote system, usually only a partial image of the data stored on the remote system is replicated on the mobile device. This is often accomplished by passing incremental updates between the two systems. For example, a user's email inbox, sent folder and other saved folders may be all be stored on a remote email server, and only the most recent 25 emails in the inbox may be stored on the user's mobile device. The emails residing on the mobile device may be updated as the user drafts additional emails from the device or as new emails received at the mail server are pushed to the mobile device. Changes made at the mobile device may be recorded at the mail server as the user, for example, sends emails via the mail server.
[0006] In many modern devices, a polling-based communication approach is used to synchronize data between the device and the server. In a polling approach, the device periodically initiates communication with the server when it determines that data needs to be synchronized. For example, data can be synchronized by polling using the hyper-text transfer protocol where the device periodically issues a hyper-text transfer protocol request to receive data from the server via a hyper-text transfer protocol response. A problem with common polling approaches is that they used fixed intervals or rely on indications sent from the server and may not be resource efficient. The present invention uses a device context that indicates the cyber or physical state of the device to determine the most appropriate times to poll the server and synchronize data. The cyber state can be any software associated state or event, such as specific data in memory. The physical state can be elements regarding the physical world surrounding the device or hardware elements on the device, such as wireless signals in proximity to the device.
[0007] The present invention may address security, bandwidth and energy efficiency concerns associated with the current art for synchronizing data on mobile device by intelligently organizing and prioritizing the synchronization of higher priority data. In a system where data is synchronized between two computing systems, such as a server and a mobile device, it may be more secure and more efficient (both with respect to bandwidth and energy usage) to only synchronize said data when it will be of use to one of the computing systems. For example, when synchronizing data to a mobile device from a central server, the mobile device only needs the data when the user is actively using the data or when the data will be immediately usable, not when the mobile device is sitting idle.
[0008] These security and efficiency concerns may be addressed by defining multiple classes of data with different synchronization priorities, by defining and monitoring the device's context (e.g. whether the device is idle, whether the user is attempting to unlock the device, whether the user is starting the email client, etc.) and synchronizing one or more classes of data based on the existing classes and the system context.
[0009] The present invention may benefit applications, including but not limited to, communications applications, such as enhanced features of chat, sharing, social networking, contact management, messaging, email, web browsing and the like; games and entertainment content applications (video games, music, video content, online content, etc.); command and control applications and features (operating system control, phone control, restricted/secured data access control, etc.); enterprise IT management applications, such as device imaging and device wiping; automotive applications, such as navigation, driver support and safety systems; and advanced security tools, such as anti-virus, firmware integrity, operating system integrity, boot loader integrity, firewalls, intrusion detection systems, and intrusion prevention systems, and the like.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 provides a schematic view of components of a system for synchronization as described in certain preferred embodiments.
[0011] FIG. 2 illustrates one method of synchronizing data between a device and a server.
[0012] FIG. 3 illustrates the process of one embodiment of the invention.
DETAILED DESCRIPTION
[0013] Referring to the invention in FIG. 1 , a device 102 may include one or more of a processor 103 , a memory 105 , a communication facility 112 , and a synchronization facility 114 . Communication facility 112 may provide an input and/or output mechanism to communicate with other network devices such as router 105 or server 104 . The communication facility 112 may also provide communication with, for example, other gateways 109 , wireless access nodes 111 , and application servers 113 to send and receive data such as packets and messages. The communication facility 112 may provide connectivity to 3G, 4G, WiFi, or other network types. Processor 103 runs software which uses the communication facility 112 and the memory 105 . Memory 105 comprises storage media such as a tangible, non-transitory computer readable medium, a programmable read only memory (PROM), or flash memory. Processor 103 may be any computer chip that is capable of executing program instruction streams that are part of a software program. Processor 103 may have multiple cores for executing multiple streams of program instructions simultaneously. The processor 103 may also have multiple sub-processors which are optimized for executing particular categories of program instructions and are controlled by the processor. The memory 105 is capable of storing and retrieving program instructions, program data, or any other data that is used by the processor. The processor 103 may store and retrieve data from the memory as a software program is executed. Memory 105 may include or store the synchronization facility 114 . Memory 105 may also include associated polies and configurations. The processor may access and update the synchronization facility 114 and associated policies and configurations. Synchronization facility 114 may communicate, through communication facility 112 , to a server 104 via a network 106 , to synchronize data 108 A, 110 A, 122 A on the device 102 with data 108 B, 110 B, 122 B on the server 104 . In some embodiments, the data may be separated into a plurality of classes, such as high priority data 108 A and B and low priority data 110 A and B. The synchronization facility 114 may initiate data synchronization of one or more classes of data based upon an input, such as a change of state from one or more resources on the device 102 . For example, the synchronization facility 114 may initiate data synchronization of the high priority data based upon an input from the power management facility 118 indicating that the device 102 is being powered on. In another example, the synchronization facility 114 may initiate data synchronization of the low priority data based upon an input from the device user interface (UI) 116 indicating that the user of the device 102 has started an application that utilizes the low priority data. In still another example, the synchronization facility 114 may initiate data synchronization of policy data 122 for use by a policy engine 124 .
[0014] A trusted code zone 126 may exist on the system as a zone of processor 103 . One or more encryption elements 128 may be are placed within the trusted code zone 126 . A trusted code zone of a processor may ensure through a cryptographic chain of trust that code executing within it has not been tampered with. Once an element is placed within the trusted processor zone for execution, the output from operations performed on it may be considered tamper-free, correct, and trusted. An example of commercial software providing trusted zone functionality is TRUSTZONE by ARM Limited. The one or more encryption elements 128 may be used to perform cryptographic operations to improve the security of the device 102 . For example, the encryption element 128 may encrypt some or all of the device's communications over communication facility 112 .
[0015] The trusted code zone 126 may also include an encryption element 128 or verification element 130 that is used to securely validate one or more elements of the context or context determination. The trusted code zone 126 protects the integrity of the encryption element 128 or verification element 130 to ensure that the context is correctly determined and/or that any communication between the device and the server is properly encrypted and/or authenticated.
[0016] In other embodiments, an external security device 132 may be used to verify elements of the context and/or encryption or authentication of the synchronization process with the server. The external security device may be a smartcard reader, such as a Bluetooth enabled reader of a government common authentication card. The external security device may also be a sleeve that is attached to the device and plugged into one or more ports on the device, such as the universal serial bus port. The external security device may also be used to verify the integrity or authenticity of data received from the server. The external security device may also be used to decrypt data received from the server. The external security device may be used instead of or in combination with the encryption element 128 and verification element 130 to perform verification, authentication, and encryption functions. For example, the external security device may encrypt a request to the server, authenticate the device or request to the server, authenticate the server or response to the device, verify the integrity and/or origin of the data received from the server, or verify the context of the device.
[0017] The device (e.g., mobile device, handheld device, laptop, or other computing device) described above can be a smart phone offering advanced capabilities including, but not limited to word processing, web browsing, gaming, e-book capabilities, an operating system, a user interface, and a full keyboard. The device may run an operating system such as SYMBIAN OS, APPLE IOS, RIM'S BLACKBERRY, WINDOWS MOBILE, Linux, PALM WEBOS, and ANDROID. The screen may be a touch screen that can be used to input data to the mobile device and the screen can be used instead of a full keyboard. The device may have the capability to run applications or communicate with applications that are provided by other network devices. The device can receive updates and other information from these applications via the communication facility.
[0018] We now describe some embodiments of a method of adaptive synchronization that may include adapting a synchronization facility 114 on a device 102 to determine when to synchronize a plurality of classes of data 108 A and B, 110 A and B, 122 A and B with data on a server 104 . FIG. 2 displays one such embodiment. At step 200 , a device context is determined based on a device state or event. At step 201 , a time is determined to synchronize data with the server based on the device context. At step 203 , data is synchronized with the server at the determined time. Further details of the operation of at least some embodiments of the invention are discussed below. In a system where data is synchronized between two computing systems, such as a server 104 and a device 102 , it may be advantageous to only synchronize said data when it will be of use to one of the computing systems. For example, when synchronizing data to a mobile device from a central server, the device may only need the data when the device user is actively using the data or when the data will be immediately usable, not when the mobile device is sitting idle. Alternately, it may be advantageous to synchronize certain data when the user stops using the mobile device so that the data will be present when the device user next begins to actively use the device. It is also advantageous to adjust the data synchronization process based on current usage state because it may allow the device to realize the full power consumption benefits in low-power states, such as when the device display is turned off, and perform more power-intensive tasks, such as network operations, when the device is in already in use.
[0019] The context determination may be used to aid in identifying an appropriate time to synchronize a device with data on a server in order to ensure that the data is up to date immediately before a user begins using the device. For example, the cyber context may be determined from one or more events indicating that the lock screen of the device is being unlocked, indicating that the user is about to begin using the device and its data should be synchronized with the server. In another embodiment, the launch of an application, such as a sensitive corporate application, may indicate that the user is about to begin using it and that the device should synchronize data specifying allowed usage of that application. In another embodiment, the device context may indicate that the device is being turned on and that the device should synchronize data before the user begins using the device. In another embodiment, the context may be the connection or disconnection from a network, indicating that data related to the network is or is not needed.
[0020] In some embodiments, a device context is determined in order to synchronize data at an advantageous time. In at least some embodiments, the context may be determined based on a device state. In some embodiments, the context may be determined based on a device event.
[0021] In at least some embodiments, the device event is an event that is related to a cyber-state of the device. Such events may include the device being locked or unlocked, the device screen turning on or off, an application launching on the device, the device connecting to or disconnecting from a network or from a specific network, or a financial transaction being in progress. For example, the device might determine the device context when the device is unlocked in order to synchronize data when a user begins engaging in use of the device. Device context can also be determined based on combinations of such events or the states the events are related to. For example, the device context might be determined when the device is unlocked while connected to a specific network. In that circumstance, synchronization might be triggered. As an example of the advantages of such a circumstance, synchronization of confidential information could be limited to when the device is connected to a secure network. Synchronization might also be triggered when the device disconnects from the secure network in order to remove the confidential data from the device when the device is not connected to the secure network.
[0022] In at least some embodiments, the device state is a physical state of the device. Such states may include the current velocity or speed of the device, the location of the device within a building as determined by an indoor navigation or trilateration system, or the presence or absence of short range data signals (e.g., BLUETOOTH, BLUETOOTH LOW ENERGY BEACON, or Near Field Communication Tag signals) in the environment around the device. For example, the location of the device within a building as determined by an indoor navigation system, consisting of proximity signaling beacons, such as Bluetooth Low Energy Beacons, may indicate that the device needs to synchronize information relevant to policies for using computing resources within that physical location. Alternately, the device might determine the device context when the device is located near a point of interest in a building. In that circumstance, synchronization of data related to the point of interest might be triggered. As an example of the advantages of such a circumstance, a user might receive information about the point of interest without having to wait for such information to be transferred to their device. In another example, the physical context may indicate the speed or velocity of the device and the device may need to synchronize data regarding the policies regarding sending text messages while in motion. The physical context may also include a quick response code or near field communication tag indicating a tagged object, such as a product, that related information should be synchronized for between the device and server. Device context can also be determined based on combinations of physical states. For example, synchronization might be triggered when the device is located near a point of interest and the current speed of the device is near zero. This is further advantageous because information is only transferred when a user is dwelling near a point of interest, minimizing data transfers when a user simply passes by a point of interest.
[0023] The physical context in place of or in addition to the cyber context can be used to determine when to poll the server. Device contexts can also be determined based on various combinations of one or more of device cyber-states, device physical states, device events related to device cyber-states, device events related to device physical states. While the above embodiments are described in relation to immediately triggering synchronization, synchronization may also be triggered at a delayed interval or canceled based on the device context. Further, an already scheduled synchronization may have its scheduled time accelerated or decelerated based on the device context. In other embodiments, other changes to synchronization patterns may also occur in response to the determination of a device context.
[0024] Once a synchronization has been scheduled or triggered, the synchronization proceeds at the time determined by the device context. Other aspects of the synchronization may also be affected by the device context. For example, in addition to determining when to synchronize data, the context may also be used to aid in determining what data to synchronize with the device. For example, the context may indicate that data relevant to a specific physical location needs to be synchronized with the device.
[0025] The device context can thus help to selectively determine what data should be synchronized or what types of data should be synchronized. In some embodiments, the device context can trigger synchronization of high priority data. In other embodiments, the device context can bar synchronization of high priority data. As an example of the advantages of such features, device context could trigger or bar the synchronization of confidential data when a user is on a secure network or not on a secure network.
[0026] In one embodiment, a user interaction with the device 102 may initiate a synchronization event. The user interaction with the device 102 may be, for example, an input to the device UI 116 . The input to the device UI 116 may one or more of locking the device 102 , unlocking the device 102 , starting an application, stopping an application, using an application, booting the device 102 , shutting down the device 102 , sending information to a remote computer, requesting information from a remote computer, or some other input, and the like. The synchronization event may be syncing files, syncing contacts, syncing mail, syncing encryption keys, syncing financial data, or other synchronizations.
[0027] In other embodiments, the synchronization event may be initiated by the device 102 or software executing on the device 102 . For example, the power management facility 118 may initiate a synchronization event when the device 102 battery reaches a certain charge.
[0028] In one example, the user may provide an input to the device UI 116 to lock the screen, and, based on that input, the synchronization facility 114 may indicate determine the device's state (i.e. the user is not intending to use the device for a period of time) and, based on the state, begin synchronizing data on the device. As a result, the device synchronizes data when the network connection is likely to be unoccupied and synchronization data does not compete for bandwidth with user data when the user is using the device.
[0029] In some embodiments, multiple classes of data are defined for synchronization between the computing systems. One class may be low priority data 110 A and B. In some embodiments, the low priority data 110 A and B may be synchronized only when the device is active. Types of data that may be in the class of low priority data may include, for example, personal emails, tweets, contact information, music files, and image files.
[0030] Another class of data may be high priority data 108 A and B. In some embodiments, the high priority data may be synchronized regardless of the current usage state of the device. Types of data that may be in the class of high priority data may include, for example, confidential business emails, text messages, voicemail notifications, instructions to wipe data on the device, and classified data. In some embodiments, there may be additional classes of data, such as medium priority data, medium-low priority data, highest priority data, and other classes of data. These classes of data may include, for example, (insert list of types of data).
[0031] In embodiments, the data being synchronized may be policy data 122 for a policy engine 124 , which may use the policy data 122 to control aspects or features of the device 102 . The policy engine 124 may generate a device-specific context, which may include one or more of the current date and time, the device location, the identity of the device user, and other context-related data. In some embodiments, the policy engine may be connected to a server 104 , such as a policy server, which may push one or more policies as policy data 122 to the policy engine 124 .
[0032] The policy engine 124 may be used to enforce one or more security policies on the device 102 . In some embodiments, the policy data 122 may include a policy for the policy engine 124 to cause the device 102 to disable functionality. For example, the policy may include a rule for disabling the camera 120 when the policy engine 124 determines that the device 102 is located in a building that prohibits the use of cameras, like a research lab. In other embodiments, the policy data 122 may include a policy for the policy engine 124 to cause the device 102 to perform operations like erasing the stored content on the device 102 . For example, the policy may include a rule for wiping all memory on the device 102 when the device user is not an authorized user or in response to an instruction from an authorized user who lost the device 102 . In embodiments, a policy that disables the camera 120 , for instance, may need only be synchronized when the device 102 is in a high-power state, as the camera 120 cannot be used in a low-power state regardless. However, in the case of a stolen or compromised device 102 , it would be necessary to erase any sensitive data stored on the device 102 immediately rather than when the device 102 is going to be interacted with.
[0033] In another embodiment, the data synchronization strategy could depend on the context of the receiving computing system. For example, the synchronization facility 114 may initiate data synchronization when events occur on the device 102 such as, when an application is started or stopped. In the policy synchronization example, a synchronization of policies between the computing systems may be triggered when an untrusted application is launched on the device 102 . In embodiments, data may be synchronized between a device and a server based on the power usage state of the device and/or based on other considerations. In embodiments, synchronization may be based on various considerations described herein separately or together.
[0034] The synchronization system could be made more or less complicated by adjusting the synchronization conditions. For example, the synchronization facility 114 may only use the network 106 while the device 102 is active and the network 106 connection is idle. In another example, the synchronization facility 114 may only use the network 106 while the device 102 is active and in a particular geo-location. In still another example, the synchronization facility 114 may only use the network 106 while the device 102 is active and the user has permitted synchronization.
[0035] In some embodiments, the data synchronized with the device may be financial data, such as a credit card number that is needed to purchase an item in the current context. The context may be, but is not limited to, a retail business, a bank, or a financial trading floor. The device may synchronize a preferred credit card processor, pin code, or other information to complete transactions in the context. The device may synchronize data related to transactions or trades currently occurring in a trading context. The synchronization of financial data ensures that financial transactions can be completed in a timely matter by having as much data needed to complete the transaction as possible already stored on the device.
[0036] In an example embodiment, the method is performed according to the algorithm shown in FIG. 3 . In state 300 , the device checks whether an unlocking event has been detected or a synchronization time has been reached. If an unlocking event has not been detected and a synchronization time has not been reached, the device remains in state 300 . If an unlocking event has been detected, the device proceeds to state 301 where it determines a time for synchronization. If a synchronization time has been reached, the device proceeds to state 302 . In state 301 , the device determines the additional device context of whether the user is connected to an encrypted network. If it is, synchronization is scheduled to occur immediately and the device proceeds to state 302 ; otherwise, synchronization is scheduled to occur later and the device returns to state 300 . In state 302 , a synchronization type is determined according to a device context. In state 302 of this embodiment, the device checks whether the device is located within a retail bank associated with the user. If the device is located within a retail bank associated with the user, then synchronization data includes transaction data. If the device is not located within a retail bank associated with the user, then synchronization data does not include transaction data. In either case, the device proceeds to state 303 . In state 303 , the device performs synchronization.
[0037] One possible device state or event suitable for use in determining a device context is a determination that a user is authorized according to the invention of U.S. Provisional Patent Application No. 61/779,931. Another possible device state or event suitable for use in determining a device context is the location-based authorization described in the invention of U.S. Provisional Patent Application No. 61/785,109. Reading of the authentication token and credential processing may be performed in a trusted zone of a processor in some embodiments in accordance with the invention of U.S. Provisional Patent Application No. 61/790,728. Inter-process communications triggered by the invention of U.S. Provisional Patent Application No. 61/781,252 may also be suitable for use in determining a device context.
[0038] While the foregoing written description of the invention describes a method of implementing the invention, those of ordinary skill will understand and appreciate that it could equally be implemented by an apparatus containing some or all of the components shown in FIG. 1 , by a non-transitory computer readable medium executed on a processor to perform the steps described, or other implementations within the scope and spirit of the invention. Further, while the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention. | A method, system, and computer-readable medium for synchronizing policy data on a device based on device usage context. By synchronizing policy data on the device based on device usage context, security, bandwidth and energy efficiency concerns associated with the current data synchronization art by intelligently organizing and prioritizing the updating of policy data in compliance with policy data. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a hose-repair tool for use in assembly and/or disassembly of a hose-coupling element with respect to an end of flexible hose, such as a hose for conduct of liquid or gaseous fluid.
It often occurs, as in the course of a relatively large-scale construction project, that flexible hose, for the flexible delivery of water, steam, compressed air, or the like, is damaged or broken through careless handling of heavy mobile equipment. Such hoses may have an inside diameter in the order of 2 inches and a wall thickness of 3/8 to 1/2 inch and are of construction suited to the task, as for example elastomeric materials that are reinforced with multiple braided plies of synthetic filaments and steel wire. The hoses are costly, and the same may be said of coupling elements fitted and tightly clamped to the end of each length of hose. When time is important to completion of a project, it frequently occurs that a complete new hose length with its end-coupling fitments will be placed into service, leaving the broken or damaged hose for discard, to be scrapped. This is, of course, a wasteful practice, and it is also wasteful of crew time if one even tries to salvage the end-coupling elements of a damaged hose; this is so, because with prolonged use and exposure, the rubber or other elastomeric of the hose becomes effectively vulcanized and locked to the end-coupling elements, and sledge-hammer and other abusive techniques may be required to reclaim an end fitting. I am unaware of any existing tool or technique for quick and damage-free recovery of an end fitting from a damaged hose.
BRIEF STATEMENT OF THE INVENTION
It is an object of the invention to provide a tool for quickly and efficiently removing an end fitting of the character indicated from a damaged length of hose.
Another object is to meet the above object with a tool that is equally applicable to the quick and efficient assembly of a new or reclaimed end fitting to the unfitted end of a new or reclaimed length of hose.
A further object is to meet the above objects with a relatively simple tool which is portable and particularly adapted to field use.
The invention achieves the foregoing objects in a unit-handling tool which provides a cylindrical anvil sized for running fit within the bore of a conventional end fitting and associated hose. The tool provides clamping elements with means for squeezing a hose securely against the anvil and at a location close to but beyond the inner axial end of an end fitting for the hose. The clamped region is longitudinally connected to screw-jacking structure which is engageable to the exposed longitudinal end of the end fitting; rotation of the jack screw in one direction, as by wrench torque, will drive a new fitting into telescoped assembly to the bore of a hose end, while rotation of the jack screw in the opposite direction will extract an end fitting from a hose. In an assembly operation, the longitudinal connection to the clamped region is in tension, and in an extraction operation, the longitudinal connection to the clamped region is in compression.
DETAILED DESCRIPTION
The invention will be described in detail for a preferred embodiment, in conjunction with the accompanying drawings, in which:
FIG. 1 is a view in side elevation, showing the tool of my invention, with certain elements broken away and in longitudinal section;
FIG. 2 is a fragmentary view in partial section to provide detail of a hose-clamping engagement at the lower end of the tool of FIG. 1;
FIG. 3 is a view in side elevation, partly broken away and in section, to show a hose-end fitting, illustratively suited for assembly to or disassembly from a hose end, using the tool of FIG. 1;
FIG. 4 is a plan view of a component part of the tool of FIG. 1; and
FIGS. 5 and 6 are plan views of component parts which are different alternatives for the part shown in FIG. 4.
Referring initially to FIG. 1, the tool of the invention is seen to comprise an elongate jack screw 10, preferably with Acme threads, and mounted at its upper end for axially retained rotation with respect to a crosspiece 11. Such a mounting can take various forms, but as shown, nuts 12, 13 and interposed washers 12', 13' bear against opposite sides of crosspiece 11, the nuts 12, 13 being welded to screw 10 in their threaded positions such that rotary freedom is available for screw 10. A bolt 14 of smaller size is welded to the upper end of screw 10, whereby the tool is adapted to torquing of the jack-screw, using a common, relatively small crescent or other wrench.
A flanged nut 15 has threaded engagement to the jack-screw 10. Nut 15 is characterized by longitudinally elongate wrench flats and by a lower flange 16, of diameter D 1 .
An annular plug 17 is loosely assembled between nut 15 and nut 13. Plug 17 has (i) a bore 18 of diameter D 2 to safely clear interference with the flats of nut 15 and (ii) a counterbore 19 to receive, seat and locate flange 16 when the tool is used in its extraction mode. When thus seated, the flats of nut 15 extend axially beyond the upper axial end of plug 17, for a wrenching hold against rotation, while the jack screw 10 is driven, as will later be explained. The exterior of plug 17 is characterized by upper wrench flats 20 and by lower threads 21, which are needed only in the extraction mode of the tool.
At the lower end of jack screw 10, a tubular anvil 22 is axially located and free to rotate, i.e., free of screw 10 so as not to rotate therewith. Axial retention is provided by upper and lower nuts 23, 24 threaded to screw 10 and anchored in position, preferably by weldments, although lock-nutted engagements at 23 and at 24 could equally well serve the axial-retention purpose, and preferably with interposed washers 23', 24' to bear against the respective ends of anvil 22, namely, with thrust against the upper end of the anvil in the extraction mode of the tool, and with thrust against the lower end of the anvil in the assembly mode of the tool. The diameter D 3 of anvil 22 is selected for close but running clearance with the bore 25 of an end fitting 26 and also for running clearance with the unstressed bore 27 of an end 28 of hose 30 fitted thereto (see FIG. 3); thus, in use of the tool, anvil 22 is freely insertable through an end fitting 26 and into a region of the hose bore (27) that is axially beyond the distal end 31 of the fitting.
In axial register and overlap with anvil 22, provision is made for applying two opposed cylindrically arcuate halves 33, 33' of clamp structure to locally squeeze hose 30 against the anvil. As shown in FIGS. 1 and 2, each half of the clamp is internally characterized by ribbing which shows as an undulation in FIG. 2, for enhanced local engagement to and indentation of the hose. Each clamp half has integral side-flange formations 34, 34' whereby pairs of bolts 35 through opposed flanges 34, 34' may be driven to apply the clamping squeeze. The clamp halves 33, 33' are each shown with integral side-lug formations 36, 36' which are bored for angularly loose, axially retained connection to separate rods 38, 38' having angularly articulated connection to opposed outboard parts 39, 39' of the crosspiece 11. Rods 38 (38') are preferably threaded and welded to axial locating nuts 40, 41 (40', 41'), for retention of the angularly loose connection to lugs 36 (36'); and at adjustably positionable intermediate positions along the threaded portions of rods 38 (38'), flat tapered finger elements 42 (42') having threaded engagement to the respective rods are radially inwardly directed, for a purpose to be described.
It is meaningful to observe that end fittings of relevance to the presently described embodiment of the invention comprise two parts, namely, a tubular part 26, as seen in FIG. 3, and a coupling-ring part 44. The coupling ring 44 has internal threads 45 and a lower-end flange 46, which is radially inward to establish a shoulder beneath a flange formation 47 of the tubular end fitting 26. Phantom outlines 48, 48' are suggestive of diametrically opposed outward lug formations which are the standard complement of commercial fittings, but these formations serve no purpose in use of the present invention. The tubular part 26 integrally includes another flange 49 which defines a shoulder against which the axial end of an assembled hose end 28 is drawn, prior to clamping; such clamping is by well-known means that is irrelevant to the invention and is therefore not shown. Peripheral ribbing on the exterior of the elongate tail 50 of part 26 is standard, for enhanced axial retention when clamped.
In use as an extraction device, the tool of FIG. 1 must operate upon the fitting parts 26, 44 of FIG. 3 to which a hose end 28 has become tightly connected, even after external clamps (not shown) along the hose end 28 have been removed. First of all, the clamp bolts 35 must be sufficiently loosened or removed, to permit outward articulation of rods 38, 38' and their associated clamp halves 33, 33' away from anvil 22. Anvil 22 is then inserted through the bore 25 of fitting 26 and into the unstressed bore of hose 30, i.e., so that the anvil axially clears the bore 25. At this point, bolts 35 and associated nuts are driven to tighten the clamp halves 33, 33' into tight local radial compression and deformation of hose 30 against anvil 22, as shown in FIG. 2. Having thus set a clamped reference for the tool, nut 15 is run down the jack screw 10 until its flange 16 contacts (or almost contacts) the convex spherically finished upper end of fitting 26. In this relationship, it is a simple matter then to engage the external threads 21 of plug 17 with the internal threads 45 of the ring part 44 of the end fitting. When threads 21/45 are sufficiently engaged, the flange (16) diameter D 1 will be concentrically located in the counterbore 19 of plug 17, and the elongate flats of nut 15 will be externally exposed for wrench-holding access above plug 17. In this engaged relationship, it will be noted that a concave spherical seat formation 29 of plug 17 may also engage the convex spherical seat formation 32 of fitting 26. By holding nut 15 against rotation, while driving the jack screw in rotation (via wrenching torque at 14), nut 15 is caused to travel upward, in firm engagement with plug 17, and with accompanying tension development in rods 38, 38'. Continued jacking action, namely, by wrenching drive at 14, and holding nut 15 against rotation, applies progressive elastic stretching force to hose 30, breaking the engagement of the hose to tail piece 50, and eventually removing the fitting 26 and its ring 44 from the hose end 28.
By way of assisting operations in the extraction mode of the tool of the invention, and while the clamp halves 33, 33' are parted and rods 38, 38' outwardly swung, the threaded finger elements 42, 42' should be manipulated on rods 38, 38' until they engage under the flange 49 of fitting 26, and with sufficient radially inward entry to initiate a wedge action between flange 49 and the adjacent end surface of hose end 28. Clamping at 33, 35 (33', 35') can then proceed as already described, followed by plug 17 engagement at 21/45 to ring 44, and subsequent jacking operation of screw 10 on nut 15. The additional result then produced by jacking travel of nut 15 upward along the screw 10 is that fingers 42, 42' are forced to apply a strong local downward push to the upper end of hose end 28 while the hose is being stretched, due to jacking reference to the clamp of hose 30 to anvil 22. There ultimately comes an instant at which all binding engagement of hose end 28 to tail 50 fails, as signified by a sudden downward separating displacement of the hose end 28 away from flange 49.
In the description thus far, plug 17 has been described as being circumferentially continuous, as the same appears in the plan view of FIG. 4. Plug 17 is not needed in the assembly mode of using the tool of FIG. 1 and therefore it may seem a nuisance to have it loose and unused in an assembly operation. That being the case, the alternative of FIG. 5 or of FIG. 6 may be adopted.
In FIG. 5, the plug 17' is identical to the plug 17 of FIG. 4, except that a radial slot 52 interrupts its circumferential continuity. Slot 52 is of width W to clear the diameter of jack screw 10, thus permitting selective assembly of plug 17' to the tool, and ready removal therefrom, as desired. In the plug 17" alternative of FIG. 6, the same feature of ready assembly to screw 10 (and removability therefrom) is provided by a construction wherein the plug 17" comprises two arcuate halves 53, 54 of a single plug; these halves have selective hinging action about a pinned connection 55 of their suitably nested lug formations 56, 57. When closed as shown in FIG. 6, the halves 53, 54 effectively complete the plug features as described in connection with FIGS. 1 and 4, and with inherent ability to withstand the circumferential compression which results from jacked tension of the threaded engagement at 21/45. When these threads are disengaged, the halves 53, 54 may be sufficiently hinged open, to permit removal from screw 10.
In use of the invention in the assembly mode, a hose 30 to receive a fitting 26 (with ring 44) is first clamped against anvil 22 in the manner already described, but at a location which clears the end of the hose by at least the length of end fitting 26. The distal end 31 of the tail 50 is then positioned for entry into the exposed open end of the hose, while nut 15 is manipulated into contact with the upper end of fitting 26; at this point, an axially short reduced cylindrical land portion 16' of the underside of flange 16 sufficiently enters the bore 25 of fitting 26, so as to maintain concentricity of nut (15) to fitting (26) engagement. Wrenching torque applied at 14 (with wrenching retention of nut 15 against rotation) may then drive nut 15, and therefore also fitting 26, for assembling entry into the hose end, to the point of the completed assembly suggested by phantom outline 28 in FIG. 3. Nut 15 can be backed off, and clamp bolts 35 released, in order to permit tool removal (i.e., anvil 22 removal) from the now-assembled hose with parts 26, 44. Conventional clamping of the assembly may then proceed.
While it has been said above that plug 17 is not necessary for assembly-mode operations, plug 17 may nevertheless provide a useful stabilizing function, in that a threaded take-up of the engagement 21/45 can be made to the point of spherical-seat engagement at 29/32, in which case, the elongate flats of nut 15 will extend above plug 17, fully accessible for retaining-wrench access to nut 15, while applying jacking torque at 14, in the direction to drive nut 15 with downward advance along jack screw 10. | The invention contemplates a unit-handling tool, suitable for field use, for selective extraction or assembly of an end fitting to an end of flexible hose. The tool features a cylindrical anvil which is sized for running clearance with the bore of the end fitting and with the bore of the hose, for insertion through and beyond the distal end of the fitting. The tool provides clamping elements with means for squeezing a hose securely against the anvil and at a location close to but beyond the inner axial end of an end fitting for the hose. The clamped region is longitudinally connected to screw-jacking structure which is engageable to the exposed longitudinal end of the end fitting; rotation of the jack screw in one direction, as by wrench torque, will drive a new fitting into telescoped assembly to the bore of a hose end, while rotation of the jack screw in the opposite direction will extract an end fitting from a hose. In an assembly operation, the longitudinal connection to the clamped region is in tension, and in an extraction operation, the longitudinal connection to the clamped region is in compression. | 1 |
RELATED APPLICATION DATA
[0001] This application claims the benefit of U.S. Provisional Application No. 60/348,383 filed Jan. 16, 2002, which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention generally relates to the field of logic design and test using design-for-test (DFT) techniques. Specifically, the present invention relates to the field of logic test and diagnosis for integrated circuits using scan or built-in self-test (BIST) techniques.
BACKGROUND
[0003] As the complexity of integrated circuits increases, it becomes more and more important to achieve very high fault coverage while minimizing test cost. Although traditional scan-based methods have been quite successful in meeting these goals for sub-million gate designs during the past few decades, for recent scan-based designs larger than one-million gates, achieving this very high fault coverage at a reasonable price has become quite difficult. This is mainly due to the fact that it requires a significant amount of test-data storage volume to store scan patterns onto the automatic test equipment (ATE). In addition, this increase in test-data storage volume has resulted in a corresponding increase in the costs related to test-application time.
[0004] Conventional approaches for solving this problem focus on either adding more memory onto the ATE or truncating part of the scan data patterns. These approaches fail to adequately solve the problem, since The former approach adds additional test cost so as not to compromise the circuit's fault coverage, while the latter sacrifices the circuit's fault coverage to save test cost.
[0005] As an attempt to solve this problem, a number of prior art design-for-test (DFT) techniques have been proposed. These solutions focus on increasing the number of internal scan chains, in order to reduce test-data volume and hence test application time without increasing, and in some cases while decreasing or eliminating the number of scan-chains that are externally accessible. This removes package limitations on the number of internal scan chains that in some cases can even exceed the package pin count.
[0006] An example of such a DFT technique is Built-In Self-Test (BIST). See U.S. Pat. No. 4,503,537 issued to McAnney (1985). BIST implements on-chip generation and application of pseudorandom scan patterns to the circuit under test eliminating all external access to the scan-chains, and hence removing any limitation on the number of internal scan-chains that can be used. BIST, however, does not guarantee very high fault coverage and must often be used together with scan ATPG (automatic test pattern generation) to cover any remaining hard-to-detect faults.
[0007] Several different approaches for compressing test data before transmitting them to a circuit under test have been proposed. See the papers co-authored by Koenemann et al. (1991), Hellebrand et al. (1995), Rajski et al. (1998), Jas et al. (2000), Bayraktaroglu et al. (2001), and U.S. Pat. No. 6,327,687 issued to Rajski et al. (2001). These methods are based on the observation that test cubes (i.e., arrangements of scan data patterns stored within the scan chains of a circuit under test) often contain a large number of unspecified (don't care) positions. It is possible to encode such test cubes with a smaller number of bits and later decompress them on-chip using an LFSR (linear-feedback shift register) based decompression scheme. This scheme requires solving a set of linear equations every time a test cube is generated using scan ATPG. Since solving these linear equations depends on the number of unspecified bits within a test cube, these LFSR-based decompression schemes often have trouble compressing an ATPG pattern without having to break it up into several individual patterns before compression, and hence have trouble guaranteeing very high fault coverage without having to add too many additional scan patterns.
[0008] A different DFT technique to reduce test data volume is based on broadcast scan. See the papers co-authored by Lee (1999) et al., Hamzaoglu et al. (1999), and Pandey et al. (2002). Broadcast scan schemes either directly connect multiple scan chains, called broadcast channels, to a single scan input or divide scan chains into different partitions and shift the same pattern into each partition through a single scan input. In these schemes, the connections between each and every scan input and its respective broadcast channels is done using either wires or buffers, without any logic gates, such as AND, OR, NAND, NOR, XOR, XNOR, MUX (multiplexer), or NOT (inverter) in between. Although it is possible to implement this scheme with practically no additional hardware overhead, it results in scan chains with very large correlation between different scan-chain data bits, resulting in input constraints that are too strong to achieve very high fault coverage.
[0009] Accordingly, there is a need to develop an improved method and apparatus for guaranteeing very high fault coverage while minimizing test data volume and test application time. The method we propose in this invention is based on broadcast scan, and thus, there is no need to solve any linear equations as a separate step after scan ATPG. A broadcast scan reordering approach is also proposed to further improve the circuit's fault coverage.
SUMMARY
[0010] Accordingly, a primary objective of this invention is to provide such an improved method and apparatus. The method we propose is based on broadcast scan, but adds a broadcaster circuit placed between the ATE (automatic test equipment) outputs and the scan chain inputs of the circuit under test. This broadcaster can be embedded on-chip or designed into the ATE. For the sake of simplicity, in this discussion we assume that the broadcaster is placed between the ATE and the integrated circuit under test without specifying where it is located physically. The following discussion applies regardless of where the broadcaster is embedded in an actual implementation.
[0011] The method according to the present invention is used to generate a broadcast scan patterns that are applied to the scan cells (memory elements) of an integrated circuit design under test. This process involves converting the virtual scan patterns stored in an ATE into broadcast scan patterns that are applied to the package scan input pins of the integrated circuit using a broadcaster. This broadcaster maps the virtual scan patterns into their corresponding broadcast scan patterns that are used to test for various faults, such as stuck-at faults, delay faults, and bridging faults in an integrated circuit. The integrated circuits tested contains multiple scan chains each consisting of any number of scan cells coupled together that store the broadcast scan pattern.
[0012] One important aspect of this invention is the design of the broadcaster circuitry. The broadcaster can be as simple as a network of combinational logic circuitry (combinational logic network) or can possibly comprise a virtual scan controller in addition to a network of combinational logic. (Please refer to FIG. 4 and FIG. 6 in DETAILED DESCRIPTION OF THE DRAWINGS for more descriptions). Adding a virtual scan controller allows the mapping performed by the broadcaster to vary depending on the internal state of the controller. The broadcaster can also be implemented using a programmable logic array. In this scheme, each ATE output is connected to a subset of the scan chain (or scan partition) inputs via the combinational logic network. Any remaining inputs of the combinational logic network are directly connected to the virtual scan controller outputs if available. During scan test, the virtual scan controller is first loaded with a predetermined value using boundary-scan or other external means. This is used to initially setup the function of the broadcaster. Later in the test, It is possible and often desirable to load in a different predetermined value into the virtual scan controller in order to change the function of the broadcaster, and this can be repeated any number of times. This allows the outputs of the broadcaster to implement different or all combinations of logic functions. Since the function of the broadcaster is a programmable function of the value stored in the virtual scan controller, there is no limitation to the number of mappings that can be implemented. This relaxes the strong input constraints of traditional broadcast scan and increases the ability to generate broadcast scan patterns to test more and possibly all testable faults. This is true since the value stored in the virtual scan controller determines the input constraints imposed on the generation of broadcast scan patterns.
[0013] While a combinational logic network is the preferred implementation for the broadcaster due to its simplicity and low overhead, the broadcaster described in this invention can comprise a virtual scan controller and any combinational logic network. The virtual scan controller can be any general finite state machine, such as an LFSR (linear feedback shift register), as long as predetermined values can be loaded into all memory elements of the finite-state machine, such as D flip-flops or D latches, when desired. The combinational logic network can includes one or more logic gates, such as AND, OR, NAND, NOR, XOR, MUX, NOT gates, or any combination of the above. This combinational logic network increases the chance of generating broadcast scan patterns that test additional faults, such as pattern resistant faults when compared to traditional broadcast scan.
[0014] Another aspect of this invention is the creation and generation of broadcast scan patterns that meets the input constraints imposed by the broadcaster. When a combinational logic network is used to implement the broadcaster, the input constraints imposed by the broadcaster allow only a subset of the scan cells to receive a predetermined logic value, either equal or complementary to the ATE output, at any time. Unlike the prior-art broadcast scan schemes which only allow all-zero and all-one patterns to be applied to the broadcast channels, the present invention allows different combinations of logic values to appear at these channels at different times. The only thing needed to generate these test patterns is to enhance the currently available ATPG tools to implement these additional input constraints. Hence. the process of generating broadcast scan patterns will be to generate patterns using an initial set of input constraints and to analyze the coverage achieved. If the fault coverage achieved is unsatisfactory, a different set of input constraints is applied and a new set of vectors are generated. This process is repeated until predetermined limiting criteria are met.
[0015] In order to reduce the number of input constraints needed to achieve very high fault coverage, the present invention may involve a broadcast scan chain reordering step before ATPG takes place. Our approach is to perform input-cone analysis from each cone output (scan cell input) tracing backwards to all cone inputs (scan cell outputs), and then to uses a maximal covering approach to reorder all cone inputs (scan cell outputs) so that only one constrained scan cell is located on a single broadcast channel during any shift clock cycle. These broadcast scan order constraints reduce, if not eliminate, the data dependency among broadcast channels associated with one ATE output. This gives the ATPG tool a better chance of generating broadcast scan patterns that achieve the target fault coverage without having to use a different set of input constraints. Please note that this applies only to integrated circuits that are still in the development phase, and hence broadcast scan reordering should be performed before the chip tapes out.
[0016] Although this process does add some CPU time to the ATPG process, it is much simpler and less computationally intensive as having to solve sets of linear equations after ATPG. The one-step “broadcast ATPG” process makes it easier to generate broadcast scan patterns as compared to LFSR-based decompression schemes. In addition, it is possible to use maximum dynamic compaction, an essential part of combinational ATPG, to fill in as many as unspecified (don't-care) positions in an effort to detect the most possible faults using a single scan pattern. This is in sharp contrast to LFSR-based decompression schemes where unspecified (don't-care) positions are desirable in order to be able to solve the linear equations needed to obtain a compressed test pattern. This is the fundamental conflict and flaw in LFSR-based decompression schemes that require starting out with a set of ATPG vectors with little compaction in order to be able to generate a set of more compact vectors. This reduces the actual compaction achieved when compared to an initial set of compact ATPG vectors testing the same faults, and allows the virtual-scan controller-based broadcast-scan method described in the present invention to cover more faults per scan test pattern than any LSFR-based decompression scheme.
THE BRIEF DESCRIPTION OF DRAWINGS
[0017] The above and other objects, advantages and features of the invention will become more apparent when considered with the following specification and accompanying drawings wherein:
[0018] [0018]FIG. 1 shows a block diagram of a conventional system for testing scan-based integrated circuits using an automatic test equipment (ATE);
[0019] [0019]FIG. 2 shows a block diagram of a broadcast scan test system, in accordance with the present invention, for testing scan-based integrated circuits using an ATE;
[0020] [0020]FIG. 3 shows a prior art broadcaster design with only pure wires;
[0021] [0021]FIG. 4 shows a block diagram of a broadcaster, in accordance with the present invention, consisting of a combinational logic network and an optional scan connector;
[0022] [0022]FIG. 5A shows a first embodiment of a broadcaster shown in FIG. 4, in accordance with the present invention, consisting of a combinational logic network;
[0023] [0023]FIG. 5B shows the inputs constraint imposed by the embodiment of a broadcaster shown in FIG. 5A;
[0024] [0024]FIG. 5C shows a second embodiment of a broadcaster shown in FIG. 4, in accordance with the present invention, consisting of a combinational logic network and a scan connector;
[0025] [0025]FIG. 5D shows the inputs constraint imposed by the embodiment of a broadcaster shown in FIG. 5C;
[0026] [0026]FIG. 6 shows a block diagram of a broadcaster, in accordance with the present invention, consisting of a virtual scan controller, a combinational logic network, and an optional scan connector;
[0027] [0027]FIG. 7 shows a first embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention;
[0028] [0028]FIG. 8 shows a second embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention;
[0029] [0029]FIG. 9 shows a third embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention;
[0030] [0030]FIG. 10 shows a fourth embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention;
[0031] [0031]FIG. 11 shows a fifth embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention;
[0032] [0032]FIG. 12 shows a sixth embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention;
[0033] [0033]FIG. 13 shows a block diagram of a compactor, in accordance with the present invention, consisting of a mask network and a XOR network or a multiple-input signature register (MISR);
[0034] [0034]FIG. 14 shows a first embodiment of a compactor shown in FIG. 13, in accordance with the present invention;
[0035] [0035]FIG. 15 shows a second embodiment of a compactor shown in FIG. 13, in accordance with the present invention;
[0036] [0036]FIG. 16A shows an embodiment of the method before reordering scan cells or changing the scan chain length for generating broadcast scan patterns to test more faults, in accordance with the present invention;
[0037] [0037]FIG. 16B shows an embodiment of the method after reordering scan cells for generating broadcast scan patterns to test more faults, in accordance with the present invention;
[0038] [0038]FIG. 16C shows an embodiment of the method after changing the scan chain length for generating broadcast scan patterns to test more faults, in accordance with the present invention;
[0039] [0039]FIG. 17 shows a flow chart of the method for reordering scan cells for fault coverage improvement, in accordance with the present invention;
[0040] [0040]FIG. 18 shows a flow chart of the method for generating broadcast scan patterns used in testing scan-based integrated circuits, in accordance with the present invention;
[0041] [0041]FIG. 19 shows a flow chart of the method for synthesizing a broadcaster and a compactor to test a scan-based integrated circuit, in accordance with the present invention; and
[0042] [0042]FIG. 20 shows an example system in which the broadcast scan test method, in accordance with the present invention, may be implemented.
DETAILED DESCRIPTION OF THE INVENTION
[0043] The following description is presently contemplated as the best mode of carrying out the present invention. This description is not to be taken in a limiting sense but is made merely for the purpose of describing the principles of the invention. The scope of the invention should be determined by referring to the appended claims.
[0044] [0044]FIG. 1 shows a block diagram of a conventional system for testing scan-based integrated circuits using an ATE. The system 101 includes a tester or external automatic test equipment (ATE) 102 and a circuit-under-test (CUT) 107 , which contains scan chains 109 .
[0045] The ATE 102 applies a set of fully specified test patterns 103 , one by one, to the CUT 107 via scan chains 109 in scan mode from external scan input pins 111 as well as from external primary input pins 113 . The CUT is then run in normal mode using the applied test pattern as input, and the response to the test pattern is captured into the scan chains. The CUT is then put back into scan mode again and the test response is shifted out to the ATE via scan chains from external scan output pins 112 as well as from external primary output pins 114 . The shifted-out test response 104 is then compared by the comparator 105 with the corresponding expected test response 106 to determine if any fault exists in the CUT, and indicates the result by the pass/fail signal 115 .
[0046] In the conventional system 101 , the number of scan chains 109 in the CUT 107 is identical to the number of the external scan input pins 111 or the number of the external scan output pins 112 . Since the number of external pins is limited in an integrated circuit, the number of scan chains in the conventional system is also limited. As a result, a large integrated circuit with a large number of scan cells (SC) 108 usually contains very long scan chains for scan test. This will result in unacceptably large test data volume and costly long test application time.
[0047] [0047]FIG. 2 shows a block diagram of a broadcast scan test system, in accordance with the present invention, for testing scan-based integrated circuits using an ATE. The system 201 includes an ATE 202 and a circuit 207 that includes a broadcaster 208 , a CUT 209 , and a compactor 213 . The CUT contains scan chains 211 .
[0048] The broadcaster 208 may contain only a combinational logic network as shown in FIG. 4 or a virtual scan controller in addition to a combinational logic network as shown in FIG. 6. The broadcaster is used to map virtual scan patterns 203 to broadcast scan patterns, where the number of bits of a virtual scan pattern is usually smaller than that of a broadcast scan pattern. The mapping function of a broadcaster is fixed if it only contains a combinational logic network. However, the mapping function is variable if it also contains a virtual scan controller. In this case, the output values of the virtual scan controller can change the mapping function that the combinational logic network realizes, thus implementing different mapping relations from external scan input pins 215 to internal scan chain inputs 219 . The compactor 213 is a combinational logic network, such as an XOR network, designed to map the internal scan chain outputs 220 to external scan output pins 216 . Note that in practice, the number of external scan input or output pins is smaller than the number of internal scan chain inputs or outputs.
[0049] Note that the element 213 can be replaced with an optional space compactor and a multiple-input signature registers (MISR). In this case, all test responses will be compressed into a single signature, which can be compared with a reference signature either in the circuit 207 or in the ATE 202 after all broadcast scan patterns have been applied.
[0050] In addition, the compactor 213 usually contains a mask network used to block several output streams from coming into a XOR compaction network or a MISR. This is useful in fault diagnosis.
[0051] [0051]FIG. 3 shows a prior art broadcaster design with only pure wires. This example broadcaster design 301 has two broadcast scan inputs 314 and 315 . The broadcast scan input 314 is connected directly to scan chains 303 to 307 while the broadcast scan input 315 is connected directly to scan chains 308 to 312 . Although the overhead of this pure-wire broadcast design is very low, the test pattern dependency among the scan chains fed by the same broadcast scan input is very high. From the point of view of automatic test pattern generation (ATPG), this pure-wire broadcast design puts a strong constraint on the inputs to scan chains. As a result, this scheme usually suffers from severe fault coverage loss.
[0052] [0052]FIG. 4 shows a block diagram of a broadcaster, in accordance with the present invention, consisting of a combinational logic network and an optional scan connector. Virtual scan patterns are applied via broadcast scan inputs 407 of the broadcaster 401 to the combinational logic network 402 . The combinational logic network implements a fixed mapping function, which converts a virtual scan pattern into a broadcast scan pattern. The broadcast scan pattern is then applied to all scan chains 409 in the CUT 404 , through an optional scan connector 403 .
[0053] The broadcaster 401 serves the purpose of providing test patterns to a large number of internal scan chains 406 through a small number of external broadcast scan input pins 407 . As a result, all scan cells SC 405 in the CUT 404 can be configured into a large number of shorter scan chains. This will help in reducing test data column and test application time. By properly designing the combinational logic network 402 , one can reduce the fault coverage loss caused by additional constraints imposed on the input pins of the scan chains.
[0054] [0054]FIG. 5A shows a first embodiment of a broadcaster shown in FIG. 4, in accordance with the present invention, consisting of a combinational logic network. In this example, a 3-bit virtual scan pattern is converted into an 8-bit broadcast scan pattern via the broadcaster 501 .
[0055] The broadcaster 501 consists of a combinational logic network 502 , which contains two inverters 503 and 507 , one XOR gate 504 , one OR gate 505 , and one NOR gate 506 . Virtual scan patterns are applied via broadcast scan inputs X2 518 to X0 520 . The combinational logic network implements a fixed mapping function, which converts a virtual scan pattern into a broadcast scan pattern. The broadcast scan pattern is then applied to all scan chains 510 to 517 via Y7 521 to Y0 528 in the CUT 508 .
[0056] [0056]FIG. 5B shows the inputs constraint imposed by the embodiment of a broadcaster shown in FIG. 5A.
[0057] The broadcaster 501 in FIG. 5A has three broadcast scan inputs X2 518 to X0 520 . Thus, there are 8 input combinations for the broadcast scan inputs as listed under <X2, X1, X0> in the table 531 . These are all possible input value combinations to the combinational logic network 502 in FIG. 5A. Therefore, as the outputs of the combinational logic network, there are 8 value combinations as listed under <Y7, Y6, Y5, Y4, Y3, Y2, Y1, Y0> in the table 531 . These are all possible logic value combinations that may appear at the inputs of the scan chains 510 to 517 in FIG. 5A, and they are the input constraints in the process of ATPG.
[0058] [0058]FIG. 5C shows a second embodiment of a broadcaster shown in FIG. 4, in accordance with the present invention, consisting of a combinational logic network and a scan connector. In this example, a 3-bit virtual scan pattern is converted into an 8-bit broadcast scan pattern via the broadcaster 561 .
[0059] The broadcaster 561 consists of a combinational logic network 562 and a scan connector 566 . The combinational logic network contains one inverter 565 , one XOR gate 563 , and one OR gate 564 . Virtual scan patterns are applied via broadcast scan inputs X2 581 to X0 583 . The combinational logic network implements a fixed mapping function, which converts a virtual scan pattern into a broadcast scan pattern. The broadcast scan pattern is then applied to all scan chains 573 to 580 through the scan connector 566 . The scan connector consists of one buffer 567 , one inverter 570 , one lock-up element LE 569 , and one spare cell SC 568 . Generally, two scan chains can be connected into one by using a buffer, an inverter, or a lock-up element in a scan connector. In addition, a spare cell can be added into an existing scan chain to change its length in order to reduce the dependency among different scan chains. This will help improve fault coverage.
[0060] [0060]FIG. 5D shows the inputs constraint imposed by the embodiment of a broadcaster shown in FIG. 5C.
[0061] The broadcaster 561 in FIG. 5C has three broadcast scan inputs X2 581 to X0 583 . Thus, there are 8 input combinations for the broadcast scan inputs as listed under <X2, X1, X0> in the table 591 . These are all possible input value combinations to the combinational logic network 562 in FIG. 5C. Therefore, as the outputs of the combinational logic network, there are 8 value combinations as listed under <Y4, Y3, Y2, Y1, Y0> in the table 591 . These are the input constraints in the process of ATPG.
[0062] [0062]FIG. 6 shows a block diagram of a broadcaster, in accordance with the present invention, consisting of a virtual scan controller, a combinational logic network, and an optional scan connector.
[0063] The broadcaster 601 consists of a virtual scan controller 602 , a combinational logic network 603 , and an optional scan connector 604 . Virtual scan patterns are applied via two types of input pins: broadcast scan inputs 608 and virtual scan inputs 609 . The broadcast scan inputs are connected directly to the combinational logic network, while the virtual scan inputs are connected directly to the virtual scan controller. In addition, the virtual scan controller may have optional virtual scan outputs 613 .
[0064] Note that the virtual scan controller 602 can be either a combinational circuit such as a decoder, or a sequential circuit such as a shift register. The logic values applied through virtual scan inputs 609 may or may not change in each clock cycle although logic values applied through broadcast scan inputs 608 change in each clock cycle. The purpose of applying virtual scan input values is to change and store a proper set-up value combination in the virtual scan controller. This set-up value combination is applied to the combinational logic network 603 through 610 in order to change the mapping function that the combinational logic network implements. Since one mapping function corresponds to one set of input constraints for ATPG, providing the capability of changing mapping functions results in more flexible input constraints for ATPG. As a result, fault coverage loss due to the broadcast scheme can be substantially reduced.
[0065] Generally, the broadcaster 601 serves two purposes during test. One purpose is to provide test patterns to a large number of internal scan chains 607 through a small number of external broadcast scan input pins 608 and virtual scan input pins 609 . As a result, all scan cells SC 606 in a circuit can be configured into a large number of shorter scan chains. This will help in reducing test data volume and test application time. Another purpose is to increase the quality of broadcast scan patterns applied from the combinational logic network 603 to all scan chains in order to obtain higher fault coverage. This is achieved by changing the values loaded into the virtual scan controller. Because of this flexibility, the combinational logic network can realize different mapping functions rather than a fixed one.
[0066] [0066]FIG. 7 shows a first embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention. The broadcaster 701 consists of a virtual scan controller 702 and a combinational logic network 705 . The virtual scan controller consists of two inverters 703 and 704 . The combinational logic network is composed of 8 XOR gates 706 to 713 . In this example, a 4-bit virtual scan pattern is converted into an 8-bit broadcast scan pattern via the broadcaster.
[0067] Obviously, the outputs 730 and 731 of the virtual scan controller 702 must have complementary values. In addition, the outputs 732 and 733 of the virtual scan controller must also have complementary values. Suppose that the values applied to the two broadcast scan inputs 728 and 729 are V1 and V2, respectively. In this case, the values appearing at scan chain inputs 734 to 743 should be P1, ˜P1, P2, ˜P2, V1, V2, P3, ˜P3, P4, ˜P4, respectively. Here P1 and ˜P1 are complementary, P2 and ˜P2 are complementary, P3 and ˜P3 are complementary, P4 and ˜P4 are complementary. In addition, P1 and P2 are either the same as V1 or are the complement of V1 while P3 and P4 are either the same as V1 or are the complement of V2. This is the input constraint for ATPG.
[0068] [0068]FIG. 8 shows a second embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention. The broadcaster 801 consists of a virtual scan controller 802 and a combinational logic network 804 . The virtual scan controller consists of a 2-to-4 decoder 803 . The combinational logic network is composed of 8 XOR gates 805 to 812 . In this example, a 4-bit virtual scan pattern is converted into an 8-bit broadcast scan pattern via the broadcaster.
[0069] Obviously, there are four possible logic value combinations for the outputs 829 to 832 of the 2-to-4 decoder 803 . They are 1000, 0100, 0010, and 0001 for the outputs 829 to 832 , respectively. Suppose the output value combination of the 2-to-4 decoder is 1000. Also suppose that the logic values applied to the two broadcast scan inputs 827 and 828 are V1 and V2, respectively. In this case, the values appearing at scan chain inputs 833 to 842 should be ˜V1, V1, V1, V1, V1, V2, ˜V2, V2, V2, V2, respectively. Here V1 and ˜V1 are complementary, while V2 and ˜V2 are complementary. This is the input constraint for ATPG. Obviously, by changing the values of virtual scan inputs 825 and 826 , one can get different set of input constraints for ATPG. This will help in improving fault coverage.
[0070] [0070]FIG. 9 shows a third embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention.
[0071] The broadcaster 901 consists of a virtual scan controller 902 and a combinational logic network 911 . The virtual scan controller consists of an 8-stage shift register with memory elements 903 to 910 . There is one virtual scan input 932 , which is the input to the shift register. There is one optional virtual scan output 935 , which is the output of the shift register. Optionally, the virtual scan input and the virtual scan output can be connected to TDI and TDO in the boundary scan design, respectively. The combinational logic network is composed of 8 XOR gates 912 to 919 . There are two broadcast scan inputs, 933 and 934 . Test patterns applied via the input 933 are broadcasted to scan chains 922 to 926 ; while test patterns applied via the input 934 are broadcasted to scan chains 927 to 931 .
[0072] The scan chains 926 and 927 are loaded directly from the broadcast scan input 933 and 934 , respectively, while the scan chains 922 to 925 , as well as the scan chains 928 to 931 , are loaded through XOR gates 912 to 915 and 916 to 919 , respectively. If the value of the memory element 903 is a logic 0, the scan chain 922 will get the identical values as those applied from the broadcast scan input 933 . If the value of the memory element 903 is a logic 1, the scan chain 922 will then get the complementary values to those applied from the broadcast scan input 933 . The same observation applies to the scan chains 923 to 925 as well as 928 to 931 . This means that, by applying a set of properly determined values to the shift register in the virtual scan controller 902 , it is possible to apply any of the 1024 combinations of logic values to the scan chains 922 to 931 in any shift cycle. As a result, any detectable fault in the CUT 920 can be detected by loading a set of properly determined logic values to the shift register and by applying a broadcast scan pattern through the inputs 933 and 934 .
[0073] From the point of view of ATPG, which tries to generate broadcast scan patterns to drive all scan chains in order to test the CUT 920 , the broadcaster configuration determined by the values of the memory elements in the shift register of the virtual scan controller 902 represents an input constraint. Suppose that the values for the memory elements 903 to 910 are 0, 1, 0, 1, 0, 1, 0, 1, respectively. In this case, the ATPG for the CUT should satisfy such an input constraint that, in any shift cycle, the scan chains 922 , 924 , and 926 have the identical value V, the scan chains 923 and 925 have the identical value ˜V that is the complement of V, the scan chains 927 , 928 , and 930 have the identical value P, the scan chains 929 and 931 have the identical value ˜P that is the complement of P.
[0074] [0074]FIG. 10 shows a fourth embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention.
[0075] The broadcaster 1001 consists of a virtual scan controller 1002 and a combinational logic network 1006 . The virtual scan controller consists of a 3-stage shift register with memory elements 1003 to 1005 . There is one virtual scan input 1023 , which is the input to the shift register. There is one optional virtual scan output 1026 , which is the output of the shift register. Optionally, the virtual scan input and the virtual scan output can be connected to TDI and TDO in the boundary scan design, respectively. The combinational logic network is composed of 4 XOR gates 1007 to 1010 . There are two broadcast scan inputs, 1024 and 1025 . Test patterns applied via the input 1024 are broadcasted to scan chains 1013 to 1017 ; test patterns applied via the input 1025 are broadcasted to scan chains 1018 to 1022 .
[0076] The major difference between the broadcaster 901 in FIG. 9 and the broadcaster 1001 in FIG. 10 is that test patterns are broadcasted directly to some scan chains instead of going through XOR gates in the broadcaster 1001 . The scan chains 1013 , 1015 , and 1017 are driven directly from the broadcast scan input 1024 . This means that, in any shift cycle, scan chains 1013 , 1015 , and 1017 will have the identical values. In addition, the scan chains 1018 , 1020 , and 1022 are driven directly from the broadcast scan input 1025 . This means that, in any shift cycle, scan chains 1018 , 1020 , and 1022 will have the identical values. As a result, by applying a set of properly determined values to the shift register in the virtual scan controller 1002 , it is only possible to apply any of the 64 combinations of logic values to the scan chains 1013 to 1022 in any shift cycle. That is, the broadcaster 1001 needs less hardware overhead at the expense of stronger constraints at the inputs to the scan chains.
[0077] [0077]FIG. 11 shows a fifth embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention.
[0078] The broadcaster 1101 consists of a virtual scan controller 1102 and a combinational logic network 1106 . The virtual scan controller consists of a 3-stage shift register with memory elements 1103 to 1105 . There is one virtual scan input 1127 , which is the input to the shift register. There is one optional virtual scan output 1130 , which is the output of the shift register. Optionally, the virtual scan input and the virtual scan output can be connected to TDI and TDO in the boundary scan design, respectively. The combinational logic network is composed of four XOR gate ( 1108 , 1109 , 1112 , 1114 ), two inverters ( 1107 , 1113 ), one AND gate ( 1110 ), and one OR gate ( 1111 ). There are two broadcast scan inputs, 1128 and 1129 . Test patterns applied via the input 1128 are broadcasted to scan chains 1117 to 1121 ; test patterns applied via the input 1129 are broadcasted to scan chains 1122 to 1126 .
[0079] The broadcaster 1101 realizes more complex broadcast mapping relations from the broadcast scan inputs 1128 and 1129 to the inputs of the scan chains 1117 to 1126 . The general form of the mapping relations can be represented by <VB, VC, V, VC, V*P, V+P, PC1, PB, PC2, P> corresponding to the inputs of the scan chains 1117 to 1126 , respectively. Here, V and P are two logic values applied from the broadcast scan inputs 1128 and 1129 in any shift cycle, respectively. VB and PB are the complements of V and P, respectively. VC equals V or VB if the output value of the memory element 1103 is a logic 0 or 1, respectively. PC1 equals P or PB if the output value of the memory element 1104 is a logic 0 or 1, respectively; PC2 equals P or PB if the output value of the memory element 1105 is a logic 0 or 1, respectively. Obviously, the broadcast mapping relation can be changed by changing VC, PC1, and PC2 through loading different sets of logic values into the shift register in the virtual scan controller 1102 . As a result, less inter-dependent test stimuli can be applied to the CUT 1115 so that higher fault coverage can be reached.
[0080] From the point of view of ATPG, which tries to generate broadcast scan patterns to drive all scan chains 1117 to 1126 in order to test the CUT 1115 , the broadcaster configuration determined by the values of the memory elements in the shift register of the virtual scan controller 1102 represents an input constraint whose general form is <VB, VC, V, VC, V&P, V+P, PC1, PB, PC2, P>. This constrained ATPG can be performed if the original sequential CUT 1115 is transformed to a combinational circuit model reflecting the constraint after the values of the memory elements are determined.
[0081] [0081]FIG. 12 shows a sixth embodiment of a broadcaster shown in FIG. 6, in accordance with the present invention.
[0082] The broadcaster 1201 consists of a virtual scan controller 1202 , a combinational logic network 1203 , and a scan connector 1207 . The combinational logic network contains two inverters 1204 and 1206 in addition to one OR gate 1205 . Virtual scan patterns are applied via broadcast scan inputs 1226 and 1227 as well as a virtual scan input TDI 1224 . One output X2 1229 from the virtual scan controller is applied to the combinational logic network, making it able to implement different mapping functions. The output values 1232 to 1236 from the combinational logic network is then applied to all scan chains 1215 to 1223 through the scan connector 1207 . The scan connector consists of one buffer 1209 , one inverter 1212 , one lock-up element LE 1211 , one spare cell SC 1210 , and one multiplexer 1208 . Generally, two scan chains can be connected into one by using a buffer, an inverter, or a lockup element in a scan connector. In addition, a spare cell can be added into an existing scan chain to reduce the dependency among different scan chains. This will help improve fault coverage. Furthermore, a multiplexer can be used to split a scan chain into two parts. As shown in FIG. 12, if the selection signal 1228 of the multiplexer 1208 is a logic 1, the scan chains 1215 and 1216 will get different input value streams. However, if the selection signal 1228 of the multiplexer 1208 is a logic 0, the scan chains 1215 and 1216 can be seen as one scan chain, and only one input value stream goes though them. Obviously, a scan connector can be used to adjust the length of scan chains in the CUT in order to shorten test time or improve fault coverage.
[0083] [0083]FIG. 13 shows a block diagram of a compactor, in accordance with the present invention, consisting of a mask network and a XOR network or a MISR.
[0084] The test responses on the outputs 1308 of the CUT corresponding to broadcast scan patterns applied on the inputs 1307 of the CUT pass through a compactor 1304 , which consists of a mask network 1305 and a XOR network or a MISR 1306 . MC 1311 is the signal used to control the mask network. It can be applied from an ATE or generated by a virtual scan controller. The mask network is used to mask some inputs to a XOR network or a MISR. This is useful in fault diagnosis. A XOR network is used to conduct space compaction, i.e. reducing the number of test response lines going out of the circuit. On the other hand, a MISR can be used to compress test responses in both space and time domains. That is, there is no need to check test results cycle by cycle when a MISR is used. On the contrary, it is only necessary to compare the signature obtained at the end of the whole test session. However, it should be noted that no unknown values (X's) are allowed to come into a MISR. This means stricter design rules should be followed.
[0085] [0085]FIG. 14 shows a first embodiment of a compactor shown in FIG. 13, in accordance with the present invention.
[0086] The test responses on the outputs 1441 to 1448 pass through a mask network 1412 and then a XOR network 1422 . The mask network consists of two groups of AND gates 1414 to 1417 and 1418 to 1421 , each group being controlled by the four outputs generated by a modified 2-to-4 decoder 1413 . In the diagnosis mode where the mode signal 1449 is a logic 1, this decoder maps logic values on MC1 1429 and MC2 1430 to one of the following combinations: 1000, 0100, 0010, and 0001. With any of these logic combination, it is clear that either group of AND gates will allow only one test response stream to pass to 1431 or 1432 . Obviously, this will help in fault diagnosis. In the test mode where the mode signal 1449 is a logic 0, this decoder will generate an all-1 logic combination. This will allow all test response streams pass to 1431 or 1432 . The XOR network 1422 consists of two groups of 4-to-1 XOR sub-networks, composed of XOR gates 1423 to 1425 and 1426 to 1428 , respectively.
[0087] [0087]FIG. 15 shows a second embodiment of a compactor shown in FIG. 13, in accordance with the present invention.
[0088] The test responses on the outputs 1540 to 1547 pass through a mask network 1512 and then a MISR 1525 . The mask network consists of two groups of AND gates 1517 to 1520 and 1521 to 1524 , each group being controlled by the four outputs of a shift register composed of memory elements 1513 to 1516 . In the diagnosis mode, this shift register can be loaded from TDI 1526 with one of the following combinations: 1000, 0100, 0010, and 0001. With any of these logic combination, it is clear that either group of AND gates will allow only one test response to pass stream to the MISR. Obviously, this will help in fault diagnosis. In the test mode, an all-1 logic combination will be loaded into the shift register. This will allow all test response streams pass to the MISR. The content of the MISR at the end of a test session can be shifted out from TDO 1529 for comparison with the expected signature.
[0089] [0089]FIG. 16A shows an embodiment of the method before reordering scan cells or changing the scan chain length for generating broadcast scan patterns to test more faults, in accordance with the present invention. A broadcaster 1601 has one broadcast scan input 1614 , which broadcasts logic values to three scan chains, 1606 , 1608 , and 1611 .
[0090] Since logic values are applied to the scan chain 1611 via an XOR gate 1604 , by properly loading the shift register in the virtual scan controller 1602 , it is possible, in any shift cycle, to apply any logic value which can be different from the one applied via scan chains 1606 and 1608 . However, scan chains 1606 and 1608 will be loaded with the same logic values in any shift cycle. As a result, the scan cells A3 1607 and B3 1610 will have the same logic value in any broadcast test patterns. Since the outputs from the scan cells A3 1607 and B3 1610 are connected to the same combinational logic block 1612 , it is possible that some faults in the combinational logic block cannot be detected due to this strong test pattern dependency. For example, in order to detect some faults in the combinational logic block, it may be necessary to have a logic 0 as the output of the scan cell A3 1607 and a logic 1 as the output of the scan cell B3 1610 . Obviously, these faults will not be detected.
[0091] [0091]FIG. 16B shows an embodiment of the method after reordering scan cells for generating broadcast scan patterns to test more faults, in accordance with the present invention. A broadcaster 1601 has one broadcast scan input 1614 , which broadcasts logic values to three scan chains, 1606 , 1608 , and 1611 .
[0092] The only difference between FIG. 16A and FIG. 16B is that, in the scan chain 1608 , the order of the scan cells B2 1609 and B3 1610 is changed. Now, although the outputs of the scan cells A3 1607 and B2 1609 have the same logic value in any shift cycle, the outputs of the scan cells A3 1607 and B3 1610 can have different logic values. As a result, this makes it possible to detect some faults that cannot be detected with the scan order shown in FIG. 16A.
[0093] [0093]FIG. 16C shows an embodiment of the method after changing the scan chain length for generating broadcast scan patterns to test more faults, in accordance with the present invention. A broadcaster 1601 has one broadcast scan input 1614 , which broadcasts logic values to three scan chains, 1606 , 1608 , and 1611 .
[0094] The only difference between FIG. 16A and FIG. 16C is that, one spare scan cell B0 1617 is added to the scan chain 1608 through a multiplexer 1618 . It is clear that, if the selection signal 1619 is a logic 1, the spare scan cell will be added to the scan chain 1608 . As a result, although the outputs of the scan cells A3 1607 and B2 1609 have the same logic value in any shift cycle, the outputs of the scan cells A3 1607 and B3 1610 can have different logic values. As a result, this makes it possible to detect some faults that cannot be detected with the scan order shown in FIG. 16A.
[0095] [0095]FIG. 17 shows a flow chart of the method for reordering scan cells for fault coverage improvement, in accordance with the present invention. This method 1700 accepts the user-supplied HDL codes 1701 together with the chosen foundry library 1702 . The HDL codes represent a sequential circuit comprised of a broadcaster, a full-scan CUT, and a compactor as shown in FIG. 2. The HDL codes and the library are then complied into an internal sequential circuit model 1704 , which is then transformed into a combination circuit model 1706 . Then, based on the original scan order information 1709 and the scan order constraints 1710 , the input-cone analysis 1707 is conducted to identify scan cells whose order needs to be changed. Then, scan chain reordering 1708 is conducted. After that, the HDL test benches and tester programs 1711 are generated while all reports and errors are saved in the report files 1712 .
[0096] [0096]FIG. 18 shows a flow chart of the method for generating broadcast scan patterns used in testing scan-based integrated circuits, in accordance with the present invention. This method 1800 accepts the user-supplied HDL codes 1801 together with the chosen foundry library 1802 . The HDL codes represent a sequential circuit comprised of a broadcaster, a full-scan CUT, and a compactor as shown in FIG. 2. The HDL codes and the library are then complied into an internal sequential circuit model 1804 , which is then transformed into a combination circuit model 1806 . Then, based on input constraints 1810 , combinational fault simulation 1807 is performed, if so required, for a number of random patterns and all detected faults are removed from the fault list. After that, combinational ATPG 1808 is performed to generate virtual scan patterns and all detected faults are removed from the fault list. If predetermined limiting criteria, such as a pre-selected fault coverage goal, are met, the HDL test benches and ATE test programs 1811 are generated while all reports and errors are saved in the report files 1812 . If the predetermined limiting criteria are not met, new input constraints 1810 will be used. For example, a new set of values can be loaded into the virtual scan controller to specify new input constraints. After that, optional random-pattern fault simulation 1807 and ATPG 1808 are performed. This iteration goes on until the predetermined limiting criteria are met.
[0097] [0097]FIG. 19 shows a flow chart of the method for synthesizing a broadcaster and a compactor to test a scan-based integrated circuit, in accordance with the present invention. This method 1900 accepts the user-supplied HDL codes 1901 together with the chosen foundry library 1902 . The HDL codes represent a sequential circuit comprised of a broadcaster, a full-scan CUT, and a compactor as shown in FIG. 2. The HDL codes and the library are then complied into an internal sequential circuit model 1904 . Then, based on the broadcaster constraints 1908 and the compacter constraints 1909 , broadcaster synthesis 1905 and compactor synthesis 1906 are conducted, respectively. After that, based on the stitching constraints 1910 , stitching 1907 is conducted to integrate the broadcaster and the compactor to the original circuit. At the end, the synthesized HDL codes 1911 are generated while all reports and errors are saved in the report files 1912 .
[0098] [0098]FIG. 20 shows an example system in which the broadcast scan test method, in accordance with the present invention, may be implemented. The system 2000 includes a processor 2002 , which operates together with a memory 2001 to run a set of the broadcast scan test design software. The processor 2002 may represent a central processing unit of a personal computer, workstation, mainframe computer or other suitable digital processing device. The memory 2001 can be an electronic memory or a magnetic or optical disk-based memory, or various combinations thereof. A designer interacts with the broadcast scan test design software run by processor 2002 to provide appropriate inputs via an input device 2003 , which may be a keyboard, disk drive or other suitable source of design information. The processor 2002 provides outputs to the designer via an output device 2004 , which may be a display, a printer, a disk drive or various combinations of these and other elements.
[0099] Having thus described presently preferred embodiments of the present invention, it can now be appreciated that the objectives of the invention have been fully achieved. And it will be understood by those skilled in the art that many changes in construction & circuitry, and widely differing embodiments & applications of the invention will suggest themselves without departing from the spirit and scope of the present invention. The disclosures and the description herein are intended to be illustrative and are not in any sense limitation of the invention, more preferably defined in scope by the following claims. | A broadcaster, system, and method for reducing test data volume and test application time in an ATE (automatic test equipment) in a scan-based integrated circuit. The scan-based integrated circuit contains multiple scan chains, each scan chain comprising multiple scan cells coupled in series. The broadcaster is a combinational logic network coupled to an optional virtual scan controller and an optional scan connector. The virtual scan controller controls the operation of the broadcaster. The system transmits virtual scan patterns stored in the ATE and generates broadcast scan patterns through the broadcaster for testing manufacturing faults in the scan-based integrated circuit. The number of scan chains that can be supported by the ATE is significantly increased. Methods are further proposed to reorder scan cells in selected scan chains, to generate the broadcast scan patterns and virtual scan patterns, and to synthesize the broadcaster and a compactor in the scan-based integrated circuit. | 6 |
FIELD OF THE INVENTION
The invention relates to rotary tool driving means, particularly for surgical operation but not necessarily confined thereto, wherein rotatable tool engageable means may be driven under power in either direction of rotation and wherein the direction of such driving may be quickly and easily determined by manually operable means.
BACKGROUND OF THE INVENTION
The concept of mechanical means for driving rotative tools, such as drilling, tapping or screw driving means, is an old one and many, possibly thousands, of such means have been offered to the trade over a period of many years. These devices have been both hand and power driven and many of them have included both speed and directional control.
However, insofar as I am aware, the majority of these devices have been designed primarily for workshop or machine shop use and few, if any, of them are appropriate for surgical use. It is self-evident that mechanisms intended for surgical use must meet a wide variety of criteria that are not necessary for use in other environments and it is therefore equally self-evident that mechanisms devised for general use are not usually acceptable for surgical use. Among such criteria are driving by nonelectric means, providing a tool small enough to be light in weight, easy to handle and of minimum obstruction to the vision of the operator, full sealing against escape of lubricant and total enclosure of all working parts excepting only the tool engaging means and the direction selecting means.
Accordingly, the objects of the invention include:
1. To provide means for rotating a tool in either rotative direction in order to perform a drilling or tapping operation or to drive or remove screw means, for example.
2. To provide means, as aforesaid, wherein such rotative direction is maintained regardless of the direction of axial pressure upon the tool.
3. To provide means, as aforesaid, wherein the direction of rotation may be quickly and easily selected, capable of operation at a moment's notice by surgical personnel and further wherein such selection may be accomplished by the operator by feel rather than under the necessity of visual observation.
4. To provide a tool, as aforesaid, wherein the motor may be housed in the handle thereof whereby to minimize the diameter of the portion of the housing containing the driving mechanism, whereby to minimize the obstruction to vision presented over the operating area to the user of the tool.
5. To provide a rotary tool, as aforesaid, wherein all operating components are fully enclosed excepting only the part actually engaging the rotating tool and a manually operable part for selecting the direction of rotation of the tool.
6. To provide a device, as aforesaid, wherein all lubricated parts are effectively sealed against escape of lubricant.
Other objects and purposes of the invention will be apparent to persons acquainted with apparatus of this general type upon reading the following specification and inspection of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a central section of a preferred device embodying the invention.
FIG. 2 is an oblique view of a detail of the clutch mechanism.
FIG. 3 is an oblique view of a detail of the direction selecting mechanism.
DETAILED DESCRIPTION
Turning now to the drawings and with principal reference, at least for the present, to FIG. 1, there is shown a device embodying the invention comprising broadly a handle section 1 and a gear and clutch section 2. Air motor means, hereinafter further identified, is contained within said handle section 1 and an output shaft 3 projects from the gear and clutch section 2 for driving by means of a conventional chuck 4 any desired threaded device or tool T.
Turning now to the apparatus in more detail, the handle section 1 comprises a casing 6 containing a conventional air motor 7 having an output shaft 8. The casing 6 carries at one end thereof, here the rightward end as appearing in FIG. 1, a pair of concentric hose fittings 9 and 11, the hose fitting 11 having a central opening 12 communicating from a supply hose X to the inlet of the motor 7 and the hose fitting 9 having a spider 13 for supporting the fitting 11. Said spider is provided with a plurality of openings of which one appears at 14 for connecting the outlet ports (not shown) of the motor 7 with the interior of the exhaust hose Y.
The output shaft 8 of the motor 7 is provided with a pin 16 radially therethrough which is received into a slot 17 of the coupling 18 whereby rotation of said shaft 8 will rotatively drive the coupling 18. The coupling 18 is rotatively supported in any suitable manner as by bearings 19 and is rotatively connected to any conventional speed reduction gearing 21. Said speed reduction gearing is provided with an output shaft 22 on which is mounted a drive pinion 23, said drive pinion being in this instance drivingly related to said shaft 22 by a set screw 24.
Turning now to the gear and clutch section 2, there is provided a lower housing 26 which is of a first diameter in a first portion 27 thereof and of a lesser diameter in a second portion 28 thereof. Said housing 26 is preferably, as here, fixed by threaded means 29 to the handle section 6. An upper housing portion 31 is threadedly related at 32 to the upper end of the housing 26 and also comprises portions of two diameters, namely a first diameter 33 which is here at least substantially equal to the diameter of the portion 27 of the lower housing 26 and a portion 34 of lesser diameter which is in this instance substantially equal to the diameter of the portion 28 of the housing 26.
Fixed within said portions 28 and 34, respectively, are a pair of sleeve bearings 36 and 37, said sleeve bearings being fixed within said housing portions in any convenient manner, as by press fitting. A shaft 3 is both rotatably and slidably received within and supported by said sleeve bearings in a manner and for purposes further developed hereinafter. One end (lower end as appearing in FIG. 1) of said shaft 3 carries the chuck 4 which chuck may as above indicated by fully conventional and adapted for receiving and firmly holding whatever kind of tool is desired to be driven by the device of the present invention. Such chucks being widely known and forming no part of the present invention, further detailing thereof is unnecessary and is hence omitted.
Concentric with said shaft 3 are two clutch units which for reference purposes herein may be identified as an upper clutch unit 41 and a lower clutch unit 42. Said upper clutch unit comprises a driven jaw clutch element 43 which is rigidly fixed as by a set screw 44 (FIG. 2) to the shaft 3 and a driving clutch element 46, said latter being provided with suitable tooth elements 47 (FIG. 2) for engaging the correspondingly toothed elements 48 of the driven clutch element 43. Said driving clutch element 46 is provided with axially directed teeth 49 which are in constant engagement with the teeth of pinion 23. Said driving clutch element 46 is here radially supported by a sleeve bearing 51 which is in turn supported on the shaft 3 and is axially fixed in position by a thrust bearing 52 located between the facing end of the upper housing portion 31 and a washer 53 which bears against a suitable shoulder 54 on the driving clutch element 46. Said thrust bearing 52 thus holds the teeth 49 of the driving clutch element 46 in driving engagement with the teeth of the pinion 23, whereby to effect constant rotation of said driving clutch element 46 regardless of the position of the shaft 3 with respect thereto.
The lower clutch element 42 is constructed and arranged similarly to the construction and arrangement of the upper clutch element 41. Specifically said lower clutch unit comprises a jaw clutch element 43A which is rigidly fixed as by a set screw 44A (FIG. 2) to the shaft 3 and a driving clutch element 46A, said latter being provided with suitable tooth elements 47A for engaging the correspondingly toothed elements 48A of the driven clutch element 43A. Said driving clutch element 46A is provided with axially directed teeth 49A which are in constant engagement with the teeth of pinion 23. Said driving clutch element 46A is here radially supported by a sleeve bearing 51A which is in turn supported on the shaft 3 and is axially fixed in position by a thrust bearing 52A located between the shoulder 25 of the lower housing 26 and a washer 53A which bears against a suitable shoulder 54A on the driving clutch element 46A. Said thrust bearing 52A thus holds the teeth 49A of the driving clutch element 46A in driving engagement with the teeth of the pinion 23 whereby to effect constant rotation of said driving clutch element 46A regardless of the position of the shaft 3 with respect thereto.
Turning now to the means for selecting the rotative direction, there is provided a cap 61 telescopically received over the upper housing 31 and axially slidably related thereto. Said cap has an internal shoulder 62 facing and positioned close to an axially facing shoulder 63 of the upper housing meber 31 and said cap further has an elongated skirt 64 telescopically arranged around the upper end of the lower housing 26. A spring 66 is captured between said face 63 and a downwardly facing shoulder 67 of said cap.
An L-shaped slot 68 (FIG. 3) is provided in said upper housing section 31, said slot having a circumferential portion 69 which is arranged circumferentially of said casing section in a plane perpendicular to the axis thereof. Said slot also has an axial section 71 which is arranged in a plane through the axis of said housing 31. The cap 61 is provided with a threaded opening 72 which contains a pin 73 threaded thereinto whose pilot tip is received within said slot 68 for purposes appearing further hereinafter.
The upper end of said cap 61 contains a thrust bearing 76 which is held on one side by spacers 77 and on the other side by a washer 78. Said washer is positioned for contact by the upper end of the shaft 3 but axial movement thereof in the direction of said shaft is limited by a snap ring 79. Thus, axial movement of said shaft 3 upwardly is limited by the washer 78 acting against the thrust bearing 76 while rotation of said shaft is still permitted by said last-named bearing.
In considering now the operation of the apparatus, let us for the sake of illustration assume that same is to be used to insert a screw temporarily into a bone for holding same in a predetermined position while other work is being performed thereon and that said screw is later, either in the same operation or in a subsequent one, to be removed under conditions which will require the application of power thereto.
With the screw, partially and schematically indicated at S, and a screw driving tool T fixed to the chuck 4, the cap 61 is rotated appropriately to permit the pilot screw 73 to enter the axial portion 71 of the slot 68. This permits said cap to respond to the spring 66 and move axially upwardly. Thus, when the screw S is placed against the bone into which it is to be inserted and even a relatively light pressure exerted thereon, it will cause the shaft 3 to move upwardly until the upwardly facing jaw clutch elements of the driven clutch member 43A engage said downwardly facing jaw clutch elements of the driving clutch member 46A. Since the teeth 49A of the latter-named driving member are constantly engaged with the teeth of the pinion 23, this will, as soon as the motor 7 is caused to rotate, effect rotation of the shaft 3 and consequently appropriate rotation of the screw S.
When it is desired to retract said screw, the cap 61 will be moved downwardly against the spring 66 and rotated to move the pilot 73 into the circumferential portion 69 of the slot 68. This causes the washer 78 to contact the upper end of the shaft 3 and drive it downwardly, thus both engaging the respective jaw clutch teeth of the driven clutch element 43 and the driving clutch element 46 and disconnecting the jaw clutch teeth of the lower driven element 43A and lower driving element 46A. Now, rotation of the motor 7 will effect rotation of the shaft 3 in the opposite direction and will do so regardless of the direction of axial thrust between the shaft 3 and the screw S. Thus, regardless of whether said shaft and the chuck carried thereby is pressed against said screw or tends to be drawn away therefrom, rotation in a reverse direction will take place. The screw is thus retracted.
The operation of the tool for other purposes, such as drilling and/or tapping or driving a Steinman pin, will be obvious from the foregoing.
Although particular preferred embodiments of the invention have 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. | Forward and reverse rotary tool, particularly for inserting and retracting a threaded element. The power-driven tool is designed primarily for surgical use and is capable of applying pressure against the free end of the threaded element during both the inserting and retracting operation, as into a bone. The shift from a driving mode to a retracting mode, or vice versa, is readily effected under conditions existing in an operating room. All movable and/or lubricated parts, other than the driven element, are housed to prevent leakage of lubricant. The tool comprises a unidirectionally driven pinion in constant engagement with a pair of counter-rotating clutch elements and means alternatively engageable with said clutch elements for rotative driving in one direction or the opposite direction. | 1 |
[0001] This application claims the priority of DE 10 2011 009 645.0 filed Jan. 27, 2011 and DE 10 2011 015 328.4 filed on Mar. 28, 2011, both applications are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] In motor vehicles with a drivetrain having an internal combustion engine and, separable by means of a friction clutch, automated gearboxes, for example automated shift gearboxes or double-clutch gearboxes with two component drivetrains—also referred to as component gearboxes—which can be connected to the internal combustion engine by means of, in each case, one friction clutch, a starting gear—for example the first or the second gear—is engaged preferably before coming to a stop in order to be able to quickly drive off again or continue driving. Here, the engagement of a starting gear is often carried out as an overrun downshift, which can result in shift shocks and shift noises which impair driving comfort.
[0003] To reduce such an impairment, the downshift may take place at a time at which the motor vehicle has slowed to a considerable degree or is already at a standstill. If, in such a situation, it is sought for example to drive off quickly again (change of mind), the delayed downshift can delay the starting process. Alternatively, the shift itself may be delayed such that the synchronization of the starting gear can be carried out with relatively low synchronization forces and therefore with a relatively minor shift jerk and low noises. This undesirably delays the shift.
[0004] Also possible is a method for the synchronization of the starting gear in which the rotational speed of the crankshaft of the internal combustion engine is increased with the friction clutch closed and the shift points are changed. Here, the drivetrain behaves in a way that a driver must become accustomed to, with increasing rotational speed of the internal combustion engine when coming to a stop. Furthermore, fuel consumption is increased. Disadvantages here are the somewhat unusual behavior (engine rotational speed increases when coming to a stop) and the increased fuel consumption.
[0005] It is therefore an object of the invention to improve a method for controlling a drivetrain with an automated double-clutch gearbox in particular with regard to a comfortable synchronization of a starting gear before the motor vehicle comes to a stop.
SUMMARY OF THE INVENTION
[0006] It should be noted at the outset that the wording “before the motor vehicle comes to a stop” does not mean imperatively that the vehicle actually comes to a stop. The vehicle may coast until it comes to a stop, or the vehicle may drive off again in the starting gear even before coming to a standstill (i.e., before actually stopping) on account of the driving situation or a demand by the driver.
[0007] Within the context of this document, the target rotational speed is to be understood to mean the rotational speed calculated from the transmission ratio of the starting gear and the gearbox output rotational speed.
[0008] Within the context of this document, an above-target input shaft rotational speed is to be understood to mean the sum of the target rotational speed of the starting gear and an offset value.
[0009] The object is thus achieved by means of a method for controlling a drivetrain in a motor vehicle having an internal combustion engine with a crankshaft ( 6 ) and having an automated double-clutch gearbox comprising a first and a second automated component gearbox ( 22 , 24 ) each with engagable and disengagable gears, each component gearbox having a gearbox input shaft ( 8 , 10 ) and a friction clutch (K 1 , K 2 ) which connects the crankshaft and the gearbox input shaft in a separable manner and is operated in an automated fashion, and also comprising a gearbox output shaft ( 12 ) which drives drive wheels, and having a control unit ( 26 ) for controlling the drivetrain, wherein, before the motor vehicle comes to a stop in an overrun mode of the motor vehicle, a shift is carried out from a gear in the second component gearbox into a starting gear in the first component gearbox (that is to say the second component gearbox does not have the starting gear), and the gear in the second component gearbox is a gear stage higher than the starting gear, wherein the starting gear in the first component gearbox is engaged by virtue of the following steps being carried out:
A disengaging a gear engaged in the first component gearbox if a gear is engaged in the first component gearbox, such that no gear is engaged in the first component gearbox, B at least partially closing the friction clutch of the first component gearbox, C opening the friction clutch of the second component gearbox, D bringing the rotational speed of the crankshaft to an above-target input shaft rotational speed by means of the internal combustion engine, E opening the friction clutch of the first component gearbox, F synchronizing the starting gear by synchronizing the gearbox input shaft rotational speed of the first component gearbox with the gearbox output shaft rotational speed by means of a shift actuator.
[0016] Here, according to the concept of the invention, it is observed that the shift shocks are less pronounced if the starting gear—for example the first or second gear—is synchronized from “above,” that is to say if the gearbox input shaft rotational speed before the synchronization is higher than the synchronized rotational speed of the gearbox input shaft, that is to say the target rotational speed.
[0017] In a further preferred embodiment of the invention, it is provided that the steps are carried out in the chronological sequence A, B, C, D, E, F.
[0018] In two alternative further preferred embodiments of the invention, it is provided that the steps are carried out in the chronological sequence A, C, B, D, E, F or C, A, B, D, E, F.
[0019] In a further preferred embodiment of the invention, it is provided that steps B and C are carried out simultaneously.
[0020] In a further alternative preferred embodiment of the invention, it is provided that, in step D, the rotational speed of the crankshaft is not brought to an above-target input shaft rotational speed by means of the internal combustion engine, but rather, in step D, the method waits until the above-target input shaft rotational speed has fallen to the crankshaft rotational speed of the internal combustion engine, and subsequently step E is initiated. Here, the crankshaft rotational speed is usually the idle rotational speed of the internal combustion engine.
[0021] In a further preferred embodiment of the invention, it is provided that the starting gear is the first gear and the gear in the second component gearbox is the second gear.
[0022] In an alternative further preferred embodiment of the invention, it is provided that the starting gear is the second gear and the gear in the second component gearbox is the third gear.
[0023] In a further preferred embodiment of the invention, it is provided that the above-target input shaft rotational speed is yielded by the sum of the target rotational speed of the starting gear, calculated from the transmission ratio of the starting gear and the gearbox output rotational speed, and an offset.
[0024] In a further preferred embodiment of the invention, it is provided that the offset is less than 200 revolutions per minute, preferably 50 to 100 revolutions per minute.
[0025] The rotational speed increase of the gearbox input shaft of the first component gearbox takes place here in such a way that the drag torques present are overcome until the synchronization is initiated already at a rotational speed of the gearbox input shaft higher than the calculated target rotational speed.
[0026] In a further preferred embodiment of the invention, it is provided that step E is carried out when or after the above-target input shaft rotational speed is reached.
[0027] In a further preferred embodiment of the invention, it is provided that, in step E, the friction clutch of the first component gearbox is only partially opened.
[0028] In a further preferred embodiment of the invention, it is provided that, after step E, or when the above-target input shaft rotational speed is reached, the rotational speed of the crankshaft is reduced again. Fuel can be saved in this way.
[0029] In a further preferred embodiment of the invention, it is provided that, during the synchronization of the starting gear, the friction clutch of the second component gearbox remains fully open.
[0030] In a further preferred embodiment of the invention, it is provided that, in step E, the friction clutch of the first component gearbox is only partially opened, and that the synchronization takes place with the friction clutch of the first component gearbox at least partially closed, and that, by means of the torque transmitted via said friction clutch, the gearbox input shaft rotational speed of the first component gearbox is kept higher than the above-target input shaft rotational speed until the gearbox input shaft rotational speed is reduced to the target rotational speed by the progressive synchronization.
[0031] In a further preferred embodiment of the invention, it is provided that, in step E, the friction clutch of the first component gearbox is only partially opened, and that the synchronization takes place with the friction clutch of the first component gearbox at least partially closed, and that, by means of the torque transmitted via said friction clutch, the gearbox input shaft rotational speed of the first component gearbox is kept at the above-target input shaft rotational speed until the gearbox input shaft rotational speed is reduced to the target rotational speed by the progressive synchronization.
[0032] In a further preferred embodiment of the invention, it is provided that, in step E, the friction clutch of the first component gearbox is only partially opened, and that the synchronization takes place with the friction clutch of the first component gearbox at least partially closed, and that, by means of the torque transmitted via said friction clutch, the gearbox input shaft rotational speed of the first component gearbox is kept higher than the target rotational speed until the gearbox input shaft rotational speed is reduced to the target rotational speed by the progressive synchronization.
[0033] In a further preferred embodiment of the invention, it is provided that the gearbox input shaft rotational speed of the first component gearbox, after an overshoot by means of regulation of the crankshaft rotational speed, is kept at a constant target rotational speed with the friction clutch of the first component gearbox at least partially closed, and a synchronization is carried out at said constant value until the gearbox input shaft rotational speed is reduced to the target rotational speed by the progressive synchronization.
[0034] In a further preferred embodiment of the invention, it is provided that the gearbox input shaft rotational speed of the first component gearbox, after an overshoot by means of regulation of the crankshaft rotational speed, is kept at a constant above-target input shaft rotational speed with the friction clutch of the first component gearbox at least partially closed, and a synchronization is carried out at said constant value until the gearbox input shaft rotational speed is reduced to the target rotational speed by the progressive synchronization.
[0035] The object is also achieved by means of a method for controlling a drivetrain in a motor vehicle having an internal combustion engine with a crankshaft and having an automated double-clutch gearbox comprising a first and a second automated component gearbox each with engagable and disengagable gears, each component gearbox having a gearbox input shaft and a friction clutch which connects the crankshaft and the gearbox input shaft in a separable manner and is operated in an automated fashion, and also comprising a gearbox output shaft which drives drive wheels, and having a control unit for controlling the drivetrain, wherein, before the motor vehicle comes to a stop in an overrun mode of the motor vehicle, a shift is carried out from a gear in the second component gearbox into a starting gear in the first component gearbox (that is to say the second component gearbox does not have the starting gear), and the gear in the second component gearbox is a gear stage higher than the starting gear, wherein the starting gear in the first component gearbox is engaged in that, after the opening of the friction clutch of the first component gearbox, a synchronization of gearbox input shaft rotational speed of the first component gearbox and gearbox output shaft rotational speed of the starting gear is initiated at a gearbox input shaft rotational speed of the first component gearbox which is higher by an offset than a target rotational speed of the gearbox input shaft of the first component gearbox yielded by the transmission ratio of the starting gear between the gearbox input shaft of the first component gearbox and the gearbox output shaft, wherein to accelerate the gearbox input shaft of the first component gearbox, the friction clutch of the first component gearbox is at least partially closed, and a crankshaft rotational speed of the internal combustion engine is increased beyond the sum of target rotational speed and offset, and the synchronization is subsequently carried out.
[0036] According to the concept of the invention, it is observed that the shift shocks are less pronounced if the starting gear—for example the first or second gear—is synchronized from “above”, that is to say if the gearbox input shaft rotational speed before the synchronization is higher than the synchronized rotational speed of the gearbox input shaft, that is to say the target rotational speed.
[0037] In a preferred embodiment of the invention, it is provided that, after a gearbox input shaft rotational speed higher than the sum of the target rotational speed and an offset is reached, the friction clutch is opened again.
[0038] In a further preferred embodiment of the invention, it is provided that, after the friction clutch is opened, the crankshaft rotational speed is reduced again. Fuel can be saved in this way.
[0039] In a further preferred embodiment of the invention, it is provided that the synchronization takes place with the friction clutch at least partially closed and, by means of the torque transmitted via said friction clutch, the gearbox input shaft rotational speed is kept higher than the sum of target rotational speed and offset until the gearbox input shaft rotational speed is reduced to the target rotational speed by the progressive synchronization.
[0040] In a further preferred embodiment of the invention, it is provided that the gearbox input shaft rotational speed, after an overshoot by means of regulation of the crankshaft rotational speed, is kept at a constant value, yielded by the sum of target rotational speed and offset, with the friction clutch at least partially closed, and a synchronization is carried out at said constant value until the gearbox input shaft rotational speed is reduced to the target rotational speed by the progressive synchronization.
[0041] During the synchronization, a shift sleeve is moved axially for example by a shift actuator, wherein friction devices of a synchronization device provide a braking action such that the rotational speeds of gearbox input shaft and gearbox output shaft, taking into consideration the transmission ratio of the starting gear, converge on one another such that a shift clutch between a loose wheel of the starting gear and the associated shaft can form a positively locking connection. As a function of the rotational speed of the gearbox output shaft resulting from the still-moving motor vehicle, a corresponding rotational speed of the gearbox input shaft is yielded as a target rotational speed. Here, the rotational speeds of the gearbox input shaft, of the gearbox output shaft and of the crankshaft are continuously measured directly or indirectly by sensors and processed by the control unit for controlling the drivetrain, for example an engine control unit which controls the internal combustion engine and a gearbox control unit which is connected thereto via a CAN bus and which controls the automated gearbox and the friction clutches, in order to calculate control variables for the internal combustion engine, the friction clutches and the gearbox.
[0042] It is self-evident that the acceleration of the gearbox input shaft to set a rotational speed above the target rotational speed need not imperatively be realized by the internal combustion engine. In fact, in unconventional drivetrains, for example hybrid drivetrains with an electric machine and/or flywheel devices and/or drivetrains with an internal combustion engine switched into a compressionless state, the kinetic energy for accelerating the gearbox input shaft can be provided by an electric machine, a rotating centrifugal mass or a crankshaft which rotates in some other way without combustion.
[0043] Further advantages and advantageous refinements of the invention are dealt with in the following figures and the description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] In the figures, in detail:
[0045] FIG. 1 shows a block circuit diagram of a known double-clutch gearbox;
[0046] FIG. 2 shows a time diagram for the execution of the method according to the invention; and
[0047] FIG. 3 shows a time diagram for the execution of the method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0048] According to FIG. 1 , a double-clutch or parallel-shift gearbox known per se has a drive shaft 6 which is driven for example by an internal combustion engine and which can be connected selectively to two input shafts 8 and 10 for conjoint rotation therewith. The torque flow from the drive shaft 6 into the input shafts 8 and 10 can be selectively controlled by means of in each case one clutch K 1 and K 2 . Different transmission ratios can be engaged between the input shaft 8 and an output shaft 12 by means of wheel pairs, only one of which is illustrated. It is likewise possible for different wheel pairs, only one of which is illustrated, to be engaged between the input shaft 10 and the output shaft 12 . To actuate the clutches K 1 and K 2 , actuators 14 and 16 are provided. To engage the wheel pairs, for example to produce a rotationally fixed connection between the wheel arranged on the input shaft 8 or 10 and the respective input shaft 8 or 10 , which wheel meshes with a respective wheel permanently connected to the output shaft 12 for conjoint rotation therewith, actuators 18 and 20 are provided which may for example each comprise a shift actuator and a selector actuator. Overall, the input shaft 8 and the output shaft 12 and also the input shaft 10 and the output shaft 12 form in each case one component gearbox 22 and 24 of the double-clutch gearbox.
[0049] The actuators 14 , 16 , 18 and 20 are controlled by an electronic control device 26 with a microprocessor and associated program and data memories, the outputs of which control in each case one of the actuators, and the inputs 28 of which are connected to sensors 30 , 32 and 34 which measure the rotational speed of the drive shaft 6 , of the input shaft 8 and of the input shaft 10 , and also further sensors for measuring operating parameters of the vehicle drivetrain, for example a sensor for measuring the rotational speed of the driven vehicle wheels, a sensor for measuring the position of a gearbox selector lever, a sensor for measuring the position of an accelerator pedal etc. The illustrated control device 26 may be connected via a bus system to further control units of the vehicle, for example an engine control unit by means of which a power controller of the engine is controlled. The actuators may be designed for example as lever-type actuators which are controlled for example by electric motors, wherein the rotation of each electric motor is measured by an incremental counter (not illustrated).
[0050] The torque that can be transmitted in each case by a clutch is important for the function of the clutch, and is stored in a memory of the control device 26 as a curve which plots the transmissible clutch torque as a function of the position of a clutch actuator, for example a clutch lever. In the event of a change of the functional state of the clutch as a result of wear and the like, the characteristic curve must be updated, which takes place by means of adaptation processes, for which purpose for example the biting point of the clutch must be checked, and adapted to any occurring changes in the clutch characteristics, during driving operation.
[0051] In the double-clutch gearbox illustrated in FIG. 1 , a gear can be engaged in each case in the respective component gearbox 22 or 24 whose clutch is open, while the effective transmission ratio of the gearbox is determined by that (active) component gearbox whose clutch is closed. If, for example, a gear is engaged in the component gearbox 22 and the clutch K 1 is closed, then said gear is active for the transmission ratio between the drive shaft 6 and the output shaft 12 . At the same time, a gear to be newly shifted may be engaged in the other component gearbox 24 . During the shift of the gearbox from the presently engaged gear into the newly engaged gear, the clutch K 1 must be opened and, for a connection between the drive shaft 6 and the output shaft 12 without an interruption in tractive force, the clutch K 2 must be closed in an overlapping manner. When the clutch K 2 takes over the transmission of torque, the gearbox would be destroyed as a result of overdetermination of the transmission ratios if at least one of the clutches K 1 , K 2 were not simultaneously slipping. Therefore, a slipping state in which at least one of the two clutches K 1 , K 2 slips is produced at least temporarily when both clutches K 1 , K 2 are simultaneously closed beyond their biting points, wherein the biting point is defined as the point beyond which the clutch transmits torque with progressive closure (at the biting point, a torque of at most a few Newton meters is transmitted).
[0052] Within the context of this document, the expressions component gearbox and component drivetrain are used synonymously.
[0053] The invention will be explained in more detail on the basis of the following two FIGS. 2 and 3 . Said figures show diagrams of different operating variables over time during a shift process for engaging a starting gear before a motor vehicle with a double-clutch gearbox conies to a halt. The shift process described below may be either a 2-1 shift with starting gear 1 , that is to say a shift from gear stage 2 to gear stage 1 with gear stage 1 as a starting gear, or a 3-2 shift with starting gear 2 , that is to say a shift from gear stage 3 to gear stage 2 with gear stage 2 as a starting gear. Within this document, the expressions gear and gear stage are used synonymously.
[0054] FIG. 2 is composed of the subdiagrams I, II, III, IV with a common time axis over time during a shift process of the starting gear. Subdiagram I schematically shows the shift travel s(SA) of the shift actuator, which can shift gears in the component gearbox of the starting gear. Subdiagram II shows the rotational speed n over time t, the solid curve n(Mot) showing the rotational speed of the crankshaft of the internal combustion engine, the dash-dotted curve n( 1 Tgt) showing the target rotational speed, calculated from the gearbox output shaft rotational speed, for the starting gear, the dotted curve n( 1 ) showing the actual gearbox input shaft rotational speed of the starting gear, and the dashed curve n( 2 ) showing the actual gearbox input rotational speed of the component gearbox which does not have the starting gear, over time t. Subdiagram III is a torque illustration of the torque M over time. Here, the solid curve M(Mot) shows the torque acting at the crankshaft of the internal combustion engine with an increasing torque intervention by the internal combustion engine, and the dash-dotted curve M(FW) shows the torque of the internal combustion engine which would occur without an increasing torque intervention by the internal combustion engine. Subdiagram IV shows a torque illustration of the frictional torque M of the two clutches involved. The dotted curve M(K 1 ) shows the frictional torque of the clutch of the component drivetrain associated with the starting gear, and the dashed curve M(K 2 ) shows the frictional torque of the clutch of the component drivetrain not associated with the starting gear.
[0055] From the juxtaposition of subdiagrams I, II, III, IV, the shift process according to the invention for engaging a starting gear before the motor vehicle comes to a stop emerges as follows: if a gear on the shaft of the starting gear is disengaged or is being disengaged—for example the third gear in the case of a 2-1 shift with a starting gear 1 —at the time t(N) by means of the shift actuator, the clutch of the component drivetrain associated with the starting gear can be partially closed. This causes the input shaft of the component drivetrain associated with the starting gear to be connected to the internal combustion engine. If, at the time t( 1 ), on account of the driving situation, the gear selection control demands the starting gear with decreasing gearbox output shaft rotational speed, that is to say with decreasing vehicle speed, the clutch of the component drivetrain not associated with the starting gear is opened. At the time t( 2 ), the clutch of the component drivetrain not associated with the starting gear is opened, and the rotational speed of the crankshaft of the internal combustion engine can be moved by means of an increasing torque intervention by the internal combustion engine in the direction of the above-target input shaft rotational speed, determined from the calculated target rotational speed of the starting gear and an additional offset n(Offs). Here, the offset n(Offs) is less than 200 revolutions per minute, preferably in the range from 50 to 100 revolutions per minute, depending for example on the deceleration of the vehicle and/or on the dynamics of the friction clutches and/or of the shift actuator. At the time t( 3 ), said above-target, input shaft rotational speed is reached, the clutch of the component drivetrain associated with the starting gear is opened, and the increasing torque intervention is ended. The shift actuator then begins the synchronization of the remaining rotational speed difference between the gearbox input shaft rotational speed of the starting gear and the calculated target rotational speed for the starting gear, which is completed at the time t( 4 ). Thereafter, corresponding to the driving situation and/or the demand by the driver, the clutch of the component drivetrain associated with the starting gear may remain open in order to allow the vehicle to coast, or may be closed for the purpose of driving off again in the starting gear.
[0056] FIG. 3 shows a similar shift process to that in FIG. 2 . Subdiagrams I-IV with a common time axis t show the same signals. Only the time t(N) at which the gear on the shaft of the starting gear is disengaged and subsequently the clutch of the component drivetrain associated with the starting gear is partially closed is shifted to a later time, such that the profile of the curve n( 1 ) is correspondingly changed.
[0057] The time t(N) may lie before or after the time t( 1 ), or else may coincide with the time t( 1 ). The time t(N) however always lies before the time t( 3 ).
[0058] In general, the shift process may also be carried out without raising the crankshaft by means of an increasing torque intervention by the internal combustion engine. The method then waits, from the time t( 2 ) in FIG. 2 or t(N) in FIG. 3 , with the friction clutch of the component drivetrain associated with the starting gear at least partially closed, until, as a result of the deceleration of the vehicle, the above-target input shaft rotational speed has fallen to the crankshaft rotational speed of the internal combustion engine, which is usually the idle rotational speed, in order to reach the time t( 3 ).
LIST OF REFERENCE SYMBOLS
[0000]
6 Drive Shaft
8 Input Shaft
10 Input Shaft.
12 Output Shaft
14 Actuator
16 Actuator
18 Actuator
20 Actuator
22 Component Gearbox
24 Component Gearbox
26 Control Device
28 Inputs
30 Sensor
32 Sensor
34 Sensor
K 1 Clutch
K 2 Clutch
n(Offs) Rotational Speed Difference
S(SA) Curve
n( 1 Tgt) Curve
n( 1 ) Curve
n( 2 ) Curve
n(Mot) Curve
M(Mot) Curve
M(FW) Curve
M(K 1 ) Curve
M(K 2 ) Curve
I Subdiagram
II Subdiagram
III Subdiagram
IV Subdiagram
M Torque.
n Rotational Speed
s Shift Travel of Shift Actuator
t Time
t( 1 ) Time
t( 2 ) Time
t( 3 ) Time
t( 4 ) Time
t(N) Time | A method for controlling a drivetrain in a motor vehicle which has an internal combustion engine with a crankshaft, an automated gearbox with engagable and disengagable gears and a gearbox input shaft and a gearbox output shaft which drives drive wheels, a friction clutch which connects the crankshaft and the gearbox input shaft in a separable manner and is operated in an automated fashion, and a control unit for controlling the drivetrain. For driving comfort, before the vehicle comes to a stop, a starting gear is engaged in an overrun mode such that, after opening the friction clutch, a synchronization of gearbox input and output shaft rotational speed of the starting gear is initiated at a gearbox input shaft rotational speed which is higher than a target rotational speed of the gearbox input shaft yielded by the transmission ratio of the starting gear between the gearbox input and output shaft. | 8 |
This application is a division of U.S. patent application Ser. No. 13/506,749 filed May 15, 2012, and pertains to assemblies for mounting wheels to the underside of a skateboard deck or roller skate boot. More specifically, it relates to a novel yoke, base, grommet, wheel and bearing combination in a skate truck to deliver high precision steering, advanced steering control, and more precise wheel alignment. Applicant claims, under 35 U.S.C. §§120, 121, the benefit of the priority of his parent application, the entire contents of which is incorporated herein by reference.
Conventional skateboards and roller skates are equipped with steering mechanisms known as trucks. The trucks are mounted on the underside of the board or boot opposite to each other, one in the front and one in the rear. Each truck carries two wheels, one at each end of the truck's axle. Each wheel is fitted with two bearings that fit into pockets integrated into the wheel body. The bearings are separated by a small gap in the middle of the wheel. This gap may be filled with a metal spacer that partially stabilizes and aligns the bearings.
Competition-level skateboarding and roller skating takes many forms, such as streetstyle, ramp riding, bowl riding, freestyle, slalom racing, and downhill racing. The equipment used by advanced skaters must meet exacting performance requirements. The truck or wheel chassis determines many of the most crucial performance characteristics.
Skate trucks serve four main purposes: 1) to connect the wheels to the deck or boot; 2) to provide wide-ranging steering response, whereby the wheel axles swivel to create a finite turning radius when, by means of lateral weight shifts, the skater tilts the deck or boot about its longitudinal axis; 3) by means of a resilient suspension system, to smoothly and predictably resist the skater's varying lateral weight shifts, thus stabilizing linear rolling motion and providing control over the steering response; and 4) by means of the same resilient suspension system, to return the deck or boot to the neutral, non-turning position after the skater discontinues a lateral weight shift. Skate wheel bearings serve the obvious purpose of aligning the wheels to the axles and minimizing rolling resistance.
Conventional skate trucks follow a basic design in which an axle pivots about an arm attached at one end to the center portion of the axle. The other end of this pivot arm is loosely fitted, at angles typically measuring 30° or 45°, into a plastic pivot cup mounted in a baseplate, thus forming a ball-like joint. A pair of doughnut-shaped grommets, usually made of rubber or urethane plastic of varying hardnesses, is mounted on a kingpin fixed at various angles in the baseplate on the side of the axle opposite the plastic cup. These grommets grasp a ring within, or extending from, the axle body so that the axle is suspended between the ball joint and the grommets. By adjusting the kingpin, the tension on the grommets may be increased or decreased, thereby varying the balance between turning stability and turning ease. Examples of this standard design are shown in U.S. Pat. No. 3,862,763, issued Jan. 28, 1975, to Gordon K. Ware; and in U.S. Pat. No. 4,109,925, issued Aug. 29, 1978 to Williams et al.
In these standard designs, the kingpin and the grommets do not precisely stabilize the axle body about the steering axis theoretically defined by the pivot arm rotating inside the plastic cup. The angle of the pivot axis tends to deteriorate as the axle tilts, so that tight turns may be difficult to achieve. The axle body is also substantially free to waiver sideward in response to side loads encountered during turns or straight-ahead riding. Steering control, range and overall performance are thereby compromised.
Furthermore, the standard design for the flexible plastic grommets results in poor steering control. Skaters control the tilt angle of the deck or boot, and thus the size of the turns they make, via lateral weight shifts of varying degree. Regardless of their hardness and no matter how they are adjusted, the conventional donut-shaped grommets do not offer an optimal or consistent pattern of resistance to such weight shifts. The result is that skaters cannot easily predict or measure how far to shift their weight to achieve turns of varying radii.
Finally, the bearings used in standard skate wheels require tolerance between their inner races and the truck axles. This means they are free to sit or rock out of alignment if one or more of the following conditions are met: the wheel bearing seats are not perfectly level; the wheel bearing seats are not precisely spaced; the spacer between the bearings is not perfectly dimensioned; no bearing spacer is used; the axle nut is not properly tensioned; and/or axle diameter and straightness are flawed. Bearings manufactured with an extended inner race element have been repurposed for skate wheels to partially address the aforementioned issues. But even these can sit or rock out of alignment if: the wheel bearing seats are not perfectly level; the wheel bearing seats are not precisely spaced; the axle nut is not properly tensioned; and/or axle diameter and straightness are flawed. The alignment distortion that may result can compromise bearing performance and longevity, directly impacting wheel rolling speed and traction.
SUMMARY OF THE INVENTION
In the present invention a high level of precision is provided to the trucks' steering action. This is accomplished by way of a cylindrical bearing which is seamlessly integrated between the axle hanger, i.e., the yoke which supports the axle on which the truck's wheels are mounted at either end, and novel grommets. The “positive” or male portions of the cylindrical bearing are formed on the grommet seats of the axle body, and to save weight this portion is made hollow, like a tube, between the pivot tip and the axle (See FIG. 5 ). The “negative” or female portions of the cylindrical bearing are formed on the surfaces of the two grommets that meet the hanger. These portions may be formed directly on the main body of the grommets, or else formed as separate elements, preferably using low friction material, and then joined to the main body of the grommets. The cylindrical bearing assembly constrains the axle body to pivot very precisely about the axis defined by the pivot arm and cup, with minimal up-down or side-to-side wavering.
The present invention improves steering control of the skateboard with novel contouring and construction of the grommets. The grommets do not feature the round doughnut shape with flat faces that is typically seen. Rather, they incorporate a substantially hexagonal shape and significantly more material on the sides, as well as a taper from broader faces that meet the hanger to narrower faces that meet the base plate and the tension nut, respectively, of a truck assembly. In addition, the narrower faces have beveled sides and join to hard end caps. Throughout a skater's turning stroke, these beveled contours constrain compressive forces to act in a substantially perpendicular orientation along the grommets' tapering outside walls, which are wider, taller and more voluminous compared to the side portions of conventional doughnut-shaped grommets. This ensures more direct and orderly resistance to compressive forces, as well as a longer compressive stroke and thus a larger steering range. In addition, the grommet's tapering sides minimize excessive “packing” of the flexible grommet material so as to create a more optimal steering control profile.
Empty pockets may be optionally formed within the grommet assemblies, for example between the grommet body and the end caps or along the sides of the female bearing portion, to further refine the steering resistance profile. Resilient elements such as wave springs may be optionally molded within the grommet bodies to enhance rebound or energy return. Laterally-flexing features may be optionally added between the female bearing elements and the grommet bodies to provide controlled speed-sensitive steering, whereby the increased side loads encountered during high speed turns will gradually move the hangers into positions of less steer.
The hard end cap joined to the lower grommet forms a mechanical lock with the contours of its seat on the base plate, thus eliminating the need for the separate round cap washer which is conventionally seen. The beveled interface between the hard end caps and the main grommet body also discourages the compressible material from flexing over the sides of its seat.
The present invention also includes bearings with integral half-spacers ending in wide flat flanges which square up and self-stabilize inside the wheels. The wide flat flanges form a self-aligning system which corrects flaws in bearing seat levelness, bearing seat spacing, axle diameter and axle straightness. The superior alignment results in reduced friction within the bearings, longer bearing life, faster rolling, and enhanced wheel grip.
Other objects and advantages of this invention will become apparent from a consideration of the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, reference should be made to the accompanying drawings in which:
FIG. 1 is a perspective view of the underside of a skateboard, partially broken away, including a depiction of the trucks of the present invention mounted on the underside of the board and movable to various positions including the positions shown in phantom;
FIG. 2 is an elevational view of the skateboard shown in FIG. 1 when a skateboarder's weight is moved toward the viewer of FIG. 2 and showing the trucks with the foreground wheels moved closer to the deck of the skateboard to accomplish a right turn of the skateboard;
FIG. 3 is a perspective view of the rear truck assembly shown in FIGS. 1 and 2 , viewing the axle hanger upwardly from underneath the skateboard deck and showing the wheels of the truck aligned in a straight ahead position;
FIG. 4 is an enlarged, exploded view of the rear truck assembly shown in FIG. 3 , with the wheel portions partially broken away;
FIG. 5 is an enlarged view, partially in perspective, of an assembled portion of the rear truck assembly shown in FIG. 5 sectioned in the direction of the arrows 5 - 5 shown in FIG. 4 ;
FIG. 6 is an enlarged and partially assembled view of the base plate and grommet assembly of the rear truck assembly shown in FIG. 4 , with the axle hanger assembly omitted;
FIG. 7 is an exploded view of elements of the axle hanger assembly of the rear truck assembly shown in FIG. 4 ;
FIG. 8 is an exploded and perspective view of central portions of the rear truck assembly shown in FIG. 4 engaged on a portion of the skateboard in a form of mounting which is an alternative to the form of mounting shown in FIG. 1 ;
FIG. 8A is an enlarged portion of the rear truck assembly and skateboard portion shown in FIG. 8 ;
FIG. 9 is an enlarged and exploded view, partially broken away, of a wheel portion of the rear truck wheel assembly shown in FIG. 4 ;
FIG. 10 is a perspective view, partially broken away, of the wheel portion of the rear truck assembly shown in FIG. 9 after the wheel portion has been assembled;
FIG. 11 is an enlarged perspective view of the assembled bearings in the wheel portion shown in FIG. 10 ;
FIG. 12 is a perspective view of one of the wheel bearings shown in FIG. 11 , broken away along the line 11 - 11 shown in FIG. 11 ;
FIG. 13 is a head on view of the broken-away face of the wheel bearing shown in FIG. 12 ; and
FIG. 14 is an elevational view of a roller skate with truck assemblies of the present invention mounted on the underside of the boot.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, one preferred embodiment of the invention is shown which is a skateboard 10 supported upon a pair of novel trucks 12 and 14 . While the preferred embodiment is a skateboard, it should be understood that the invention, including its various elements, will also be applicable to other rolling platform vehicles, such as a roller skate, which are powered by the rider, or by gravity, or by some combination thereof. Also, in the following paragraphs the truck 12 which is mounted toward the rear of the skateboard will be the truck principally described, but it will also be understood that the truck 14 which is mounted toward the front of the skateboard has an identical construction.
However, the kingpin, or post, 20 on which the rear truck wheels 22 articulate has a longitudinal axis extending toward the rear end, or tail, 24 of the skateboard deck 26 . The kingpin, or post 30 in truck 14 mounted toward the front, or nose 32 of the skateboard has a longitudinal axis which extends toward the nose of the skateboard, and the front truck wheels 34 articulate on this post. The front and rear trucks, 14 and 12 respectively, are thus oppositely disposed to each other.
As shown in FIG. 1 in solid lines, wheels 22 and 34 of the rear truck 12 and front truck 14 , respectively, are in a straight-forward attitude when the axles, such as axle 36 of the rear truck 12 , are normal to a straight-line path incorporating the longitudinal axis of the skateboard 10 . The skateboarder's weight, if one were present on top of the skateboard, would normally be equally distributed toward both outer edges of the skateboard. As shown in phantom in FIG. 1 , and in solid lines in FIG. 2 , the trucks are turned to execute a right turn, with a skateboarder's weight predominantly on the side of the skateboard closest to the viewer in FIG. 2 . With the skateboarder's weight thus distributed, the weight on the right side of the skateboard pressing downwardly in the direction of arrows 42 causes the wheels on the right side of the skateboard to move closer together. The nose of the board swings in an arc toward the right and the tail of the skateboard swings in an arc out to the left to orient the longitudinal axis of the skateboard deck in a right turn.
Rear truck 12 is illustrated in FIG. 3 in its assembled state with wheels 22 mounted on axle 36 . An exploded view of the truck 12 is shown in FIG. 4 . A yoke, or hanger, 44 supports the axle 36 and connects the entire truck and wheel bearing assembly to the skateboard 10 . The body portion 46 of the yoke is supported on its pivot tip 50 in a pivot cup 52 which is, in turn housed in a pocket in one end of truck base plate 54 . The pivot cup is usually made of a lubricious plastic so that the pivot tip 50 can easily turn in a multitude of directions within it as the yoke 44 moves in an arcuate path about the base plate 54 to dispose the wheels 22 from one position to another.
A first aperture 56 is formed in a central portion of the yoke 44 , spaced apart from the pivot tip 50 , so that the yoke 44 may also be mounted on the kingpin 20 . A cylindrical bearing member 60 , which is part of the yoke, is located adjacent to the first aperture. The size of the opening through that aperture is somewhat larger than the diameter of the kingpin, or post, 20 so that the yoke 44 is able to be fitted to the post during assembly and tilted in various attitudes while the yoke is maintained on the post. As shown in FIG. 5 , the post 20 has a head portion 62 lodged in the base plate 54 and extends through the first aperture 56 to a distal end 64 where it is engaged by a tension nut 66 . Preferably, the tension nut is threadably engaged on the post's distal end 64 so that pressure on the elements of the yoke mounting assembly between the head of post 20 and its distal end 64 can be adjusted.
A resilient first grommet 70 is engaged on the post 20 and the bearing member 60 on the underside of the yoke 44 . Grommet 70 has a first face 72 which is engaged on the cylindrical bearing member 60 adjacent the first aperture 56 . The outer surface of the bearing member 60 is cylindrical, and a cylindrically shaped groove bearing surface 73 in first face 72 is configured for complementary engagement with the cylindrical surface of the bearing member 60 in the yoke. Such an engagement precisely regulates and restricts the arcuate movement of the yoke. The bearing member is able to rotably slide through its interface with the first face of the grommet as the flat surface adjacent the bearing member 60 compresses the flat surface on the grommet adjacent the bearing groove 73 .
In the body portion 46 of yoke 44 there is a recessed area 74 which has perimeter walls adjacent to the bearing member 60 . A collar section 76 of the first grommet is sized and configured to be fitted within those walls, and thus the walls of the recess grasp and hold the grommet in place. Preferably, the configuration of the walls forms a hexagonal recess, but similar configurations of the walls which intercept the collar section 76 may be used.
The first grommet 70 has sides which taper from a larger end of the grommet adjacent to the first face 72 to a smaller end adjacent to a second face 80 . Those sides form a cone from the first face 72 at the larger end of the grommet which is configured for engagement with the bearing member 60 to the second face 80 at the smaller end of the grommet which is configured for proximate engagement with the tension nut 66 . Preferably the second face 80 is beveled. An end cap 82 which has a beveled surface 84 complementary to the second face 80 is interposed on post 20 between the grommet and the tension nut. The end cap 82 is also made of a harder material than grommet 70 , thus forming a hard, stable point of connection for the grommet at its second face 80 . The sides of the grommet are provided with external fissures 86 , and on the interior, as will shortly be described, the sides are internally hollow.
These configurations of grommet 70 produce improved results for a skater. The contours of the beveled second face 80 constrain compressive forces to act in a substantially perpendicular orientation along the tapering outside walls, which are wider, taller and more voluminous compared to the side portions of conventional doughnut-shaped grommets. This insures more direct and orderly resistance to compressive forces, as well as a longer compressive stroke and thus a larger steering range. The tapering sides minimize excessive packing of the flexible grommet material so as to create a more optimal steering control profile.
In the first face 72 , the cylindrical bearing member 60 may be formed directly on the main body of grommet 70 , or else formed as a separate element, preferably using low friction material, and then joined to the main body of the grommet. The cylindrical bearing assembly constrains yoke 44 to pivot very precisely about the axis defined by the pivot tip 50 and the pivot cup 52 with minimal up-down or side-to-side wavering. At the same time the cylindrical bearing assembly resists the increased side loads encountered during high-speed turns more progressively compared to conventional constructions. As side loads increase, the female bearing portion of the bearing in the first face, i.e., cylindrically shaped groove 73 , will gradually, rather than suddenly, flex under pressure from the male bearing portion in the yoke, i.e., cylindrical bearing member 60 , thereby allowing the yoke 44 to gradually move into positions of progressively slower steering, which is a desirable speed-sensitive steering effect.
As shown particularly in FIG. 5 , the cylindrical bearing member 60 includes a cylindrical side 60 a across the aperture 56 from the first grommet 70 . Side 60 a of the cylindrical bearing faces the base plate 54 . A second grommet 90 , which is quite similar to first grommet 70 , has a cylindrically shaped bearing surface 92 with which the second grommet engages the bearing surface 62 a . There is a recessed area 94 on the base plate side of the yoke into which a first face 96 of the second grommet fits in a non-rotating manner like the first grommet does on the other side of yoke 44 . When first face 96 is so inserted, the second grommet engages its bearing surface 92 with the bearing 60 .
As shown in FIGS. 4 and 6 , fissures 100 are formed on the outside walls of the second grommet, and the interiors of the grommet walls are hollowed out as at hollows 102 . A second face 104 on the second grommet, spaced apart from the second grommet's first face 96 , contains a plurality of first locking members 106 . An end cap 110 , which is disposed on post 20 , has a plurality of second locking members 112 arranged for complementary engagement with the first locking members 106 . The surfaces of the locking members may be ridged, and the surfaces 114 of the second grommet and 116 of the end cap 110 which engage each other beveled, as illustrated in FIG. 6 . The end cap 110 also includes a face 118 opposite the second locking members 112 which can be fixed on the base plate 54 , as by incorporating a cup 120 which is arranged to match the configurations 122 on the base plate.
The second grommet, like the first, incorporates a substantially hexagonal shape and significantly more material on the sides, as well as a taper from broader faces that meet the yoke to narrower faces that meet the base plate. The narrow second face has beveled sides that join the hard end cap. Throughout a skater's turning stroke, these beveled surfaces constrain compressive forces to act in a substantially perpendicular orientation along the second grommet's tapering walls, which are wider, taller and more voluminous compared to the side portions of conventional doughnut-shaped grommets. This insures more direct and orderly resistance to compressive forces, as well as a longer compressive stroke and thus a larger steering range. In addition, the grommet's tapering sides minimise packing of the flexible grommet material so as to create a more optimal steering control profile.
The end cap 110 forms a mechanical lock with the contours of its seat on the base plate, thus eliminating any need for a separate round cap washer in an assembly that is conventionally seen. The beveled interface between the end cap and the second grommet body also discourages compressible material from flexing over the sides of its seat.
A normal type of mounting for a truck such as truck 12 onto the underside of a skateboard is shown in FIG. 1 , that is, to fasten the flanges 126 to the underside of deck 26 with screw or bolts inserted through the mounting holes 128 in the flanges. An alternative type of mounting is shown in FIG. 8A , known as a “dropthrough” mounting. In that alternative, skateboard deck 132 is provided with an opening 134 which is arranged to fit the footprint of a truck structure beyond the flanges, i.e., a socket into which the superstructure of the truck fits. Truck 136 is mounted this way in FIG. 8A . The superstructure 138 of the truck extends through the deck 132 , leaving flanges 140 on the other side, i.e., the top side of the deck. The truck is fastened in place using one or more bolts 142 . The deck-engaging surfaces of flanges 140 feature a convex contour to provide complementary engagement in the “dropthrough” mounting on the top surface of the deck, which normally has a concave contour. Small circular flat areas are preserved in the corners of the base plate's top surfaces to form stable seats for the mounting nuts when the truck is assembled onto the deck in the normal manner shown in FIG. 1 .
The wheel bearing assembly 150 shown in FIGS. 9 through 13 is also an important part of the entire truck 12 for accomplishing smooth and improved control of a skateboard or roller-skate. In wheels 22 , shown in an enlarged, broken-away view in FIG. 9 , first and second ball bearings are enclosed in casings 152 and 154 . On the first casing, 152 , there is a bell 156 on the exterior of the casing, and on the second casing 154 there is a second bell 160 . The bells 156 and 160 meet, as shown in FIGS. 10 and 11 , when the casings 152 and 154 are assembled on axle 36 and disposed in their respective housings 164 and 166 . The bells 156 and 160 are slideably disposed on each other but may also be positively joined inside the wheel.
More particularly, the wheel bearing assembly 150 for wheel 22 on axle 36 incorporates a first ball bearing casing 152 which has an inner casing portion 170 for bearing balls in a first race 172 and an extension section 174 beyond the first race. At the extremity of the extension section there is a first flange 176 which extends outwardly from axle 36 when the axle is disposed in channel 180 through the bearing. The second ball bearing casing 154 mirrors casing 152 , with an inner, second race and culminating in a flange beyond the second race which extends outwardly from axle 36 . The first and second flanges are disposed against each other within the wheel when they are assembled in their housings, or bearing seats, and disposed on axle 36 . When so disposed, the two flanges square up and self-stabilize. They form a self-aligning system which compensates for flaws in bearing seat levelness, bearing seat spacing, axle diameter and axle straightness. Thfs assembly results in reduced friction within the bearings, longer bearing life, faster rolling, and enhanced wheel grip.
As shown in FIG. 14 , the truck and wheel bearing assembly more particularly described above may be mounted on the underside of a roller-skate deck 184 to which a skater's boot 186 is affixed. Rear truck 12 A and front truck 14 A are illustrated with their rear and front wheels 22 A and 34 A, respectively, turned in the same attitude as the wheels illustrated in FIG. 2 are turned beneath a skateboard.
Those skilled in the art will readily see that while numerous detailed variations of the above-described embodiments if this invention may be made, the true scope of the invention is to be determined by the following claims | An improved skateboard or roller-skate truck is disclosed containing a novel yoke, base, grommet, wheel and bearing combination which delivers high precision steering, advanced steering control and more precise wheel alignment. The truck comprises a base plate and a yoke having a body portion with an aperture through it. There is a bearing member in the yoke next to the aperture. A post is mounted in the base plate and extends through the aperture in the yoke. A novel resilient grommet with a bearing surface on its face is mounted on the post and engages the bearing member in the yoke to restrict arcuate movements of the yoke. A novel wheel bearing is also disclosed which incorporates paired ball bearing casings with bell-shaped members on the outside of each casing slideably meeting each other inside a skate wheel where the bells self adjust the bearings to accommodate imperfections in the bearing seat levelness, bearing seat spacing, axle diameter and axle straightness. | 5 |
[0001] This application is a continuation-in-part of application Ser. No. 09/484,320 filed Jan. 18, 2000.
FIELD OF INVENTION
[0002] This invention relates generally to compositions of cyanine dye bioconjugates with bioactive molecules for diagnosis and therapy, and particularly for visualization and detection of tumors.
BACKGROUND OF THE INVENTION
[0003] Several dyes that absorb and emit light in the visible and near-infrared region of electromagnetic spectrum are currently being used for various biomedical applications due to their biocompatibility, high molar absorptivity, and/or high fluorescence quantum yields. The high sensitivity of the optical modality in conjunction with dyes as contrast agents parallels that of nuclear medicine, and permits visualization of organs and tissues without the undesirable effect of ionizing radiation.
[0004] Cyanine dyes with intense absorption and emission in the near-infrared (NIR) region are particularly useful because biological tissues are optically transparent in this region (B. C. Wilson, Optical properties of tissues. Encyclopedia of Human Biology, 1991, 5, 587-597). For example, indocyanine green, which absorbs and emits in the NIR region, has been used for monitoring cardiac output, hepatic functions, and liver blood flow (Y-L. He, et al., Measurement of blood volume using indocyanine green measured with pulse-spectrometry: Its reproducibility and reliability. Critical Care Medicine, 1998, 26(8), 1446-1451; J. Caesar, et al., The use of Indocyanine green in the measurement of hepatic blood flow and as a test of hepatic function. Clin. Sci. 1961, 21, 43-57), and its functionalized derivatives have been used to conjugate biomolecules for diagnostic purposes (R. B. Mujumdar, et al., Cyanine dye labeling reagents: Sulformdocyanine succinimidyl esters. Bioconjugate Chemistry, 1 993, 4(2), 105-1 11; U.S. Pat. No. 5,453,505; WO 98/48846; WO 98/22146; WO 96/17628; WO 98/48838).
[0005] A major drawback in the use of cyanine dye derivatives is the potential for hepatobiliary toxicity resulting from the rapid clearance of these dyes by the liver (G. R. Cherrick, et al., Indocyanine green: Observations on its physical properties, plasma decay, and hepatic extraction. J. Clinical Investigation, 1960, 39, 592-600). This is associated with the tendency of cyanine dyes in solution to form aggregates, which could be taken up by Kupffer cells in the liver.
[0006] Various attempts to obviate this problem have not been very successful. Typically, hydrophilic peptides, polyethyleneglycol or oligosaccharide conjugates have been used, but these resulted in long-circulating products, which are eventually still cleared by the liver. Another major difficulty with current cyanine and indocyanine dye systems is that they offer a limited scope in the ability to induce large changes in the absorption and emission properties of these dyes. Attempts have been made to incorporate various heteroatoms and cyclic moieties into the polyene chain of these dyes (L. Strekowski, et al., Substitution reactions of a nucleofugal group in hetamethine cyanine dyes. J. Org. Chem., 1992, 57, 4578-4580; N. Narayanan, and G. Patonay, A new method for the synthesis of heptamethine cyanine dyes: Synthesis of new near infrared fluorescent labels. J. Org. Chem., 1995, 60, 2391-2395; U.S. Pat. Nos. 5,732,104; 5,672,333; and 5,709,845), but the resulting dye systems do not show large differences in absorption and emission maxima, especially beyond 830 nm where photoacoustic diagnostic applications are very sensitive. They also possess a prominent hydrophobic core, which enhances liver uptake. Further, most cyanine dyes do not have the capacity to form starburst dendrimers, which are useful in biomedical applications.
[0007] For the purpose of tumor detection, many conventional dyes are useful for in vitro applications because of their highly toxic effect on both normal and abnormal tissues. Other dyes lack specificity for particular organs or tissues and, hence, these dyes must be attached to bioactive carriers such as proteins, peptides, carbohydrates, and the like to deliver the dyes to specific regions in the body. Several studies on the use of near infrared dyes and dye-biomolecule conjugates have been published (G. Patonay and M. D. Antoine, Near-infrared Fluorogenic Labels: New Approach to an Old Problem, Analytical Chemistry, 1991, 63:321A-327A and references therein; M. Brinkley, A Brief Survey of Methods for Preparing Protein Conjugates with Dyes, Haptens, and Cross-Linking Reagents, Perspectives in Bioconjugate Chemistry 1993, pp. 59-70, C. Meares (Ed), ACS Publication, Washington, D.C.; J. Slavik, Fluorescent Probes in Cellular and Molecular Biology, 1994, CRC Press, Inc.; U.S. Pat. No. 5,453,505; WO 98/48846; WO 98/22146; WO 96/17628; WO 98/48838). Of particular interest is the targeting of tumor cells with antibodies or other large protein carriers such as transferrin as delivery vehicles (A. Becker, et al., “Transferrin Mediated Tumor Delivery of Contrast Media for Optical Imaging and Magnetic Resonance Imaging”, Biomedical Optics meeting, Jan. 23-29, 1999, San Jose, Calif.). Such an approach has been widely used in nuclear medicine applications. Its major advantage is the retention of a carrier's tissue specificity, since the molecular volume of the dye is substantially smaller than the carrier. However, this approach does have some serious limitations in that the diffusion of high molecular weight bioconjugates to tumor cells is highly unfavorable, and is further complicated by the net positive pressure in solid tumors (R. K. Jain, Barriers to Drug Delivery in Solid Tumors, Scientific American 1994, 271:58-65. Furthermore, many dyes in general, and cyanine dyes, in particular, tend to form aggregates in aqueous media that lead to fluorescence quenching.
[0008] Therefore, there is a need for dyes that could prevent dye aggregation in solution, that are predisposed to form dendrimers, that are capable of absorbing or emitting beyond 800 nm, that possess desirable photophysical properties, and that are endowed with tissue-specific targeting capability.
SUMMARY OF THE INVENTION
[0009] The invention is directed to compositions, and methods of preparing the compositions, of low molecular weight biomolecule-dye conjugates to enhance tumor detection. The inventive compositions preserve the fluorescence efficiency of the dye molecules, do not aggregate in solution, form starburst dendrimers, are capable of absorbing or omitting light in the near infrared region (beyond 800 mm), and can be rendered tissue-specific.
[0010] In one embodiment, the inventive composition comprises cyanine dyes of general formula 1.
[0011] wherein W 3 and X 3 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 3 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 3 is selected from the group consisting of —(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 1 is a single or a double bond; B 1 , C 1 , and D 1 may the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 1 , B 1 , C 1 , and D 1 may together form a 6- to 12-membered carbocyclic ring or a 6- to 12-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 3 and b 3 independently vary from 0 to 5; R 1 to R 4 , and R 29 to R 37 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a bioactive peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
[0012] In a second embodiment, the inventive composition comprises cyanine dyes of general formula 2.
[0013] wherein W 4 and X 4 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 4 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 )—NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 4 is selected from the group consisting of —(CH 2 )—CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 2 is a single or a double bond; B 2 , C 2 , and D 2 may be the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 2 , B 2 , C 2 , and D 2 may together form a 6- to 1 2-membered carbocyclic ring or a 6- to 1 2-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 4 and b 4 independently vary from 0 to 5; R 1 to R 4 , and R 45 to R 57 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a bioactive peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
[0014] In a third embodiment, the inventive composition comprises cyanine dyes of general formula 3
[0015] wherein W 5 and X 5 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 5 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ), —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 5 is selected from the group consisting of —(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Dm, —(CH 2 )—N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 3 is a single or a double bond; B 3 , C 3 , and D 3 may be the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 3 , B 3 , C 3 , and D 3 may together form a 6- to 12-membered carbocyclic ring or a 6- to 12-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 5 is independently from 0 to 5; R 1 to R 4 , and R 58 to R 66 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a bioactive peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
[0016] In a fourth embodiment, the inventive composition comprises cyanine dyes of general formula 4
[0017] wherein W 6 and X 6 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 6 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a -CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 CH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Bm, CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 CH 2 ) b —CH 2 NR 3 R 4 ; Z 6 is selected from the group consisting of —(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH—Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO—Dm, —(CH 2 )—N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 4 is a single or a double bond; B 4 , C 4 , and D 4 may be the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 4 , B 4 , C 4 , and D 4 may together form a 6- to 12-membered carbocyclic ring or a 6- to 12-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 6 is independently from 0 to 5; R 1 to R 4 , and R 67 to R 79 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH or —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a bioactive peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
[0018] The invention will be further appreciated in light of the following figures, detailed description, and examples.
BRIEF DESCRIPTION OF THE FIGURES
[0019] The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the Patent and Trademark Office upon request and payment of the necessary fee.
[0020] [0020]FIG. 1 shows the reaction pathway for the synthesis of bis-carboxylic acid cyanine dyes.
[0021] [0021]FIG. 2 shows the reaction pathway for the synthesis of tetracarboxylic acid cyanine dyes.
[0022] [0022]FIG. 3 shows the reaction pathway for the synthesis of polyhydroxycarboxylic acid dyes.
[0023] [0023]FIG. 4 shows the reaction pathway for the synthesis of non-aggregating cyanine dyes.
[0024] [0024]FIG. 5 shows the reaction pathway for the synthesis of long wavelength absorbing dyes.
[0025] [0025]FIG. 6 shows the reaction pathway for the synthesis of cyanine dye bioconjugates.
[0026] FIGS. 7 A-F represent images at 2 minutes and 30 minutes post injection of indocyanine green (ICG) into rats with various tumors.
[0027] FIGS. 8 A-B show a comparison of the uptake of ICG (FIG. 8A) and Cytate 1 (FIG. 8B) in rats with the pancreatic acinar carcinoma (CA20948).
[0028] FIGS. 9 A-B show images of rats with the pancreatic acinar carcinoma (CA20948) 45 minutes (FIG. 9A) and 27 hours (FIG. 9B) post injection of Cytate 1.
[0029] [0029]FIG. 10 is an image of individual organs taken from a rat with pancreatic acinar carcinoma (CA20948) about 24 hours after injection with Cytate 1.
[0030] [0030]FIG. 11 is an image of bombesinate in an AR42-J tumor-bearing rat 22 hours after injection.
[0031] [0031]FIG. 12 is the clearance profile of Cytate 1 from the blood of a normal rat.
[0032] [0032]FIG. 13 is the clearance profile of Cytate 1 from the blood of a pancreatic tumor-bearing rat.
[0033] [0033]FIG. 14 is the clearance profile of Cytate 2 from the blood of a normal rat.
[0034] [0034]FIG. 15 is the clearance profile of Cytate 2 from the blood of a pancreatic tumor-bearing rat.
[0035] [0035]FIG. 16 is the clearance profile of Cytate 4 from the blood of a normal rat.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The novel compositions of the present invention comprising dyes of formulas 1 to 4 offer significant advantages over those currently described in the art. These inventive dyes form starburst dendrimers which prevent aggregation in solution by preventing intramolecular and intermolecular ordered hydrophobic interactions, and have multiple attachment sites proximal to the dye chromophore for ease of forming bioactive molecules. The presence of rigid and extended chromophore backbone enhances their fluorescence quantum yield and extends their maximum absorption beyond 800 nm. Conjugation of biomolecules to these dyes is readily achievable.
[0037] The inventive bioconjugates of the present invention also exploit the symmetric nature of the cyanine and indocyanine dye structures by incorporating one to ten receptor targeting groups in close proximity to each other, such that the receptor binding can be greatly enhanced due to a cooperative effect. Accordingly, several cyanine dyes containing one or more targeting domains have been prepared and tested in vivo for biological activity.
[0038] The inventive dye-bioconjugates of formulas 1 to 4 are useful for various biomedical applications. These include, but are not limited to, tomographic imaging of organs, monitoring of organ functions, coronary angiography, fluorescence endoscopy, detection, imaging, and therapy of tumors, laser guided surgery, photoacoustic methods, and sonofluorescent methods.
[0039] Specific embodiments to accomplish some of the aforementioned biomedical applications are given below. The novel dyes of the present invention are prepared according to methods well known in the art and are illustrated in FIGS. 1 - 5 .
[0040] [0040]FIG. 1 illustrates the synthetic scheme for bis-carboxylic acid cyanine dyes, where A=CH 2 or CH 2 OCH 2 ; R=COOH; R=COOH, NHFmoc; CO 2 t—Bu; SO 3 ; R 1 =R 2 =H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2).
[0041] [0041]FIG. 2 illustrates the synthetic scheme for tetracarboxylic acid cyanine dyes, where A=CH 2 or CH 2 OCH 2 ; R 1 =R 2 =H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2).
[0042] [0042]FIG. 3 illustrates the synthetic scheme for polyhydroxycarboxylic acid cyanine dyes.
[0043] [0043]FIG. 4 illustrates the synthetic scheme for non-aggregating cyanine dyes.
[0044] [0044]FIG. 5 illustrates the synthetic scheme for long wavelength-absorbing tunable cyanine dyes.
[0045] In one embodiment, the inventive bioconjugates have the Formula 1 wherein W 3 and X 3 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) OH)CH 3 , —C((CH 2 ) a OH) 2 , —C((CH 2 ) a CO 2 H)CH 3 , —C((CH 2 ) a CO 2 H) 2 , —C((CH 2 ) a NH 2 )CH 3 , —C((CH 2 ) a NH 2 ) 2 , C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 3 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 3 is selected from the group consisting of —(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 1 is a single or a double bond; B 1 , C 1 , and D 1 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 1 , B 1 , C 1 , and D 1 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 3 and b 3 are independently from 0 to 3; R 1 to R 4 , and R 29 to R 37 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxyaryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of bioactive peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d are independently from 1 to 30.
[0046] In a second preferred embodiment, the inventive bioconjugates have the general Formula 2, wherein W 4 and X 4 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) a OH)CH 3 , —C((CH 2 ) a OH) 2 , —C((CH 2 ) a CO 2 H)CH 3 , —C((CH 2 ) a CO 2 H) 2 , —C((CH 2 ) a NH 2 )CH 3 , —C((CH 2 ) a NH 2 ) 2 , —C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 4 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 4 is selected from the group consisting of —(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 2 is a single or a double bond; B 2 , C 2 , and D 2 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 2 , B 2 , C 2 , and D 2 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 4 and b 4 are independently from 0 to 3; R 1 to R 4 , and R 45 to R 57 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxyaryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a bioactive peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d independently from 1 to 30.
[0047] In a third embodiment, the inventive bioconjugates have the general Formula 3 wherein W 5 and X 5 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) a OH)CH 3 , —C((CH 2 ) a OH) 2 , —C((CH 2 ) a CO 2 H)CH 3 , —C((CH 2 ) a CO 2 H) 2 , —C((CH 2 ) a NH 2 )CH 3 , —C((CH 2 ) a NH 2 ) 2 , —C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 5 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 5 is selected from the group consisting of —(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 3 is a single or a double bond; B 3 , C 3 , and D 3 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 3 , B 3 , C 3 , and D 3 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 5 is from 0 to 3; R 1 to R 4 , and R 58 to R 66 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxy aryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a bioactive peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d are independently from 1 to 30.
[0048] In a fourth embodiment, the inventive bioconjugates have the general Formula 4 wherein W 6 and X 6 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) a OH)CH 3 , —C((CH 2 ) a OH) 2 , —C((CH 2 ) a CO 2 H)CH 3 , —C((CH 2 ) a CO 2 H) 2 , —C((CH 2 ) a NH 2 )CH 3 , C((CH 2 ) a NH 2 ) 2 , —C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 6 is selected from the group consisting of —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 6 is selected from the group consisting of —(CH 2 ) a —CONH—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Dm, —(CH 2 ) a —NHCO—Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 4 is a single or a double bond; B 4 , C 4 , and D 4 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 4 , B 4 , C 4 , and D 4 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 6 is from 0 to 3; R 1 to R 4 , and R 67 to R 79 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxy aryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH—Bm, —(CH 2 ) a —NHCO—Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO—Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a bioactive peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d are independently from 1 to 30.
[0049] This invention is also related to the method of conjugating the inventive dyes to peptides or biomolecules by solid phase or solution synthesis methods. FIG. 6 illustrates the synthetic scheme for bioconjugates incorporating the cyanine dyes of FIGS. 1 - 5 , using automated peptide synthesis in a solid support, where A=CH 2 or CH 2 OCH 2 ; R 1 =R 2 =H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2); AA=amnio acids; R=CONH peptide; R′=R (bis conjugate) or COOH (mono conjugate); {circle over (P)}=solid support; {circle over (P)}′=presence or absence depends on R′ definition.
[0050] This invention is also related to the method of preventing fluorescence quenching. It is known that cyanine dyes generally form aggregates in aqueous media, leading to fluorescence quenching. Where the presence of a hydrophobic core in the dyes leads to fluorescence quenching, the addition of a biocompatible organic solvent, such as 1-50% dimethylsulfoxide (DMSO) for example, restored fluorescence by preventing aggregation and allowed in vivo organ visualization.
[0051] The dye-biomolecule conjugates are used for optical tomographic, endoscopic, photoacoustic and sonofluorescent applications for the detection and treatment of tumors and other abnormalities.
[0052] Dye-biomolecule conjugates of the invention are also used for localized therapy. This may be accomplished by attaching a porphyrin or photodynamic therapy agent to a bioconjugate, shining light of appropriate wavelength for detection and treatment of the abnormality.
[0053] The inventive conjugates can also be used for the detection of the presence of tumors and other abnormalities by monitoring the blood clearance profile of the conjugates, for laser assisted guided surgery for the detection of small micrometastases of, e.g., somatostatin subtype 2 (SST-2) positive tumors, upon laparoscopy, and for diagnosis of atherosclerotic plaques and blood clots.
[0054] The compositions of the invention can be formulated into diagnostic and therapeutic compositions for enteral or parenteral administration. These compositions contain an effective amount of the dye along with conventional pharmaceutical carriers and excipients appropriate for the type of administration contemplated. For example, parenteral formulations advantageously contain the inventive agent in a sterile aqueous solution or suspension. Parenteral compositions may be injected directly or mixed with a large volume parenteral composition for systemic administration. Such solutions also may contain pharmaceutically acceptable buffers and, optionally, electrolytes such as sodium chloride.
[0055] Formulations for enteral administration may vary widely, as is well known in the art. In general, such formulations are liquids, which include an effective amount of the inventive agent in aqueous solution or suspension. Such enteral compositions may optionally include buffers, surfactants, thixotropic agents, and the like. Compositions for oral administration may also contain flavoring agents and other ingredients for enhancing their organoleptic qualities.
[0056] The diagnostic compositions are administered in doses effective to achieve the desired enhancement. Such doses may vary widely, depending upon the particular dye employed, the organs or tissues to be imaged, the imaging equipment being used, and the like. The diagnostic compositions of the invention are used in the conventional manner. The compositions may be administered to a patient, typically a warm-blooded animal, either systemically or locally to the organ or tissue to be imaged, and the patient then subjected to the imaging procedure.
[0057] The inventive compositions and methods represent an important approach to the synthesis and use of novel cyanine and indocyanine dyes with a variety of photophysical and chemical properties. The combination also represents an important approach to the use of small molecular targeting groups to image tumors by optical methods. The invention is further detailed in the following Examples, which are offered by way of illustration and are not intended to limit the scope of the invention in any manner.
EXAMPLE 1
[0058] Synthesis of Bis(ethylcarboxymethyl)indocyanine Dye
[0059] (FIG. 1, R 1 , R 2 =fused phenyl; A=CH 2 , n=1 and R=R′=CO 2 H)
[0060] A mixture of 1,1,2-trimethyl-[1H]-benz[e]indole (9.1 g, 43.58 mmoles) and 3-bromopropanoic acid (10.0 g, 65.37 mmoles) in 1,2-dichlorobenzene (40 mL) was heated at 110° C. for 12 hours. The solution was cooled to room temperature and the red residue obtained was filtered and washed with acetonitrile:diethyl ether (1:1) mixture. The solid obtained was dried under vacuum to give 10 g (64%) of light brown powder. A portion of this solid (6.0 g; 16.56 mmoles), glutaconaldehyde dianil monohydrochloride (2.36 g, 8.28 mmoles) and sodium acetate trihydrate (2.93 g, 21.53 mmoles) in ethanol (150 mL) were refluxed for 90 minutes. After evaporating the solvent, 40 mL of a 2 N aqueous HCl was added to the residue. The mixture was centrifuged and the supernatant was decanted. This procedure was repeated until the supernatant became nearly colorless. About 5 mL of water:acetonitrile (3:2) mixture was added to the solid residue and lyophilized to obtain 2 g of dark green flakes. The purity of the compound was established with 1 H-NMR and liquid chromatography-mass spectroscopy (LC-MS)
EXAMPLE 2
[0061] Synthesis of Bis(pentylcarboxymethyl)indocyanine Dye
[0062] (FIG. 1, R 1 , R 2 =fused phenyl; A=CH 2 , n=4 and R=R′=CO 2 H)
[0063] A mixture of 1,1,2-trimethyl-[1H]-benz[e]indole (20 g, 95.6 mmoles) and 6-bromohexanoic acid (28.1 g, 144.1 mmoles) in 1,2-dichlorobenzene (250 mL) was heated at 110° C. for 12 hours. The green solution was cooled to room temperature and the brown solid precipitate formed was collected by filtration. After washing the solid with 1,2-dichlorobenzene and diethyl ether, the brown powder obtained (24 g, 64%) was dried under vacuum at room temperature. A portion of this solid (4.0 g; 9.8 mmoles), glutaconaldehyde dianil monohydrochloride (1.4 g, 5 mmoles) and sodium acetate trihydrate (1.8 g, 1 2.9 mmoles) in ethanol (80 mL) were refluxed for 1 hour. After evaporating the solvent, 20 mL of a 2 N aqueous HCl was added to the residue. The mixture was centrifuged and the supernatant was decanted. This procedure was repeated until the supernatant became nearly colorless. About 5 mL of water:acetonitrile (3:2) mixture was added to the solid residue and lyophilized to obtain about 2 g of dark green flakes. The purity of the compound was established with 1 H-NMR and LC-MS.
EXAMPLE 3
[0064] Synthesis of Bisethylcarboxymethvlindocyanine Dye
[0065] (FIG. 1, R 1 =R 2 =H; A=CH 2 , n=1 and R=R′=CO 2 H)
[0066] This compound was prepared as described in Example 1 except that 1,1,2-trimethylindole was used as the starting material.
EXAMPLE 4
[0067] Synthesis of Bis(hexaethyleneglycolcarboxymethyl)indocyanine Dye
[0068] (FIG. 1, R 1 =R 2 =fused phenyl; A=CH 2 OCH 2 , n=6 and R=R′=CO 2 H)
[0069] This compound was prepared as described in Example 1 except that {overscore (ω)}-bromohexaoxyethyleneglycolpropiolic acid was used in place of bromopropanoic acid and the reaction was carried out in 1,2-dimethoxypropane.
EXAMPLE 5
[0070] Synthesis of Bisethylcarboxymethylindocyanine Dye
[0071] (FIG. 2, R 1 =R 2 =fused phenyl; A=CH 2 , and n=0)
[0072] A solution of 50 ml of dimethylformamide and benzyl bromoacetate (16.0 g, 70 mmol) was stirred in a 100-mL three-neck flask. Solid potassium bicarbonate (7.8 g, 78 mmol) was added. The flask was purged with argon and cooled to 0° C. with an ice bath. To the stirring mixture was added dropwise a solution of ethanolamine (1.9 g, 31 mmol) and 4 ml of dimethylformamide over 5 minutes. After the addition was complete the mixture was stirred for 1 hour at 0° C. The ice bath was removed and the mixture stirred at room temperature overnight. The reaction mixture was partitioned between 100 ml of methylene chloride and 100 ml of saturated sodium bicarbonate solution. The layers were separated and the methylene chloride layer was again washed with 100 ml of saturated sodium bicarbonate solution. The combined aqueous layers were extracted twice with 25 ml of methylene chloride. The combined methylene chloride layers were washed with 100 ml of brine, and dried over magnesium sulfate. The methylene chloride was removed with aspirator vacuum at about 35° C., and the remaining dimethylformamide was removed with vacuum at about 45° C. The crude material was left on a vacuum line overnight at room temperature.
[0073] The crude material was then dissolved in 100 ml of methylene chloride at room temperature. Triphenylphosphine (8.91 g, 34 mmol) was added and dissolved with stirring. An argon purge was started and the mixture was cooled to 0° C. with an ice bath. The N-bromosuccinimide (6.05 g, 34 mmol) was added portionwise over two minutes. The mixture was stirred for 1.5 hours at 0° C. The methylene chloride was removed with vacuum and gave purple oil. This oil was triturated with 200 ml of ether with constant manual stirring. During this time the oil became very thick. The ether solution was decanted and the oil was triturated with 100 ml of ether. The ether solution was decanted and the oil was again triturated with a 100 ml portion of ether. The ether was decanted and the combined ether solution was allowed to stand for about two hours to allow the triphenylphosphine oxide to crystallize. The ether solution was decanted from the crystals and the solid was washed with 100 ml of ether. The volume of the combined ether abstracts was reduced with vacuum until a volume of about 25 ml was obtained. This was allowed to stand over night at 0° C. Ether (10 ml) was added to the cold mixture, which was mixed to suspend the solid. The mixture was percolated through a column of 45 g of silica gel and eluted with ether, 75 ml fractions were collected. The fractions that contained product, as determined by thin layer chromatography, were pooled and the ether was removed with vacuum. This yielded 10.1 g of crude product. The material was flash chromatographed on silica gel with hexane, changing to 9:1 hexane:ether. The product-containing fractions were pooled and the solvents removed with vacuum. This yielded 7.4 g (57% yield) of pure product.
[0074] A mixture of 10% palladium on carbon (1 g) and a solution of the benzyl ester (10 g) in 150 ml of methanol was hydrogenolyzed at 25 psi for two hours. The mixture was filtered over celite and the residue was washed with methanol. The solvent was evaporated to give a viscous oil in quantitative yield.
[0075] Reaction of the bromide with 1,1,2-trimethyl-[1H]-benz[e]indole was carried out as described in Example 1.
EXAMPLE 6
[0076] Bis(ethylcarboxymethyldihydroxyl)indocyanine Dye (FIG. 3)
[0077] The hydroxy-indole compound is readily prepared by a known method (P. L. Southwick, et al., One pot Fischer synthesis of (2,3,3-trimethyl-3-H-indol-5-yl)-acetic acid derivatives as intermediates for fluorescent biolabels. Org. Prep. Proced. Int. Briefs, 1988, 20(3), 279-284). Reaction of p-carboxymethylphenylhydrazine hydrochloride (30 mmol, 1 equiv.) and 1,1-bis(hydroxymethyl)propanone (45 mmole, 1.5 equiv.) in acetic acid (50 mL) at room temperature for 30 minutes and at reflux for one minute gives (3,3-dihydroxymethyl-2-methyl-3-H-indol-5-yl)-acetic acid as a solid residue. The reaction of 3-bromopropyl-N,N-bis(carboxymethyl)amine, which was prepared as described in Example 5, with the intermediate indole and subsequent reaction of the indole intermediate with glutaconaldehyde dianil monohydrochloride (see Example 1) gives the desired product.
EXAMPLE 7
[0078] Synthesis of Bis(propylcarboxymethyl)indocyanine Dye (FIG. 4)
[0079] The intermediate 2-chloro-1-formyl-3-hydroxymethylenecyclohexane was prepared as described in the literature (G. A. Reynolds and K. H. Drexhage, Stable heptamethine pyrylium dyes that absorb in the infrared. J. Org. Chem., 1977, 42(5), 885-888). Equal volumes (40 mL each) of dimethylformamide (DMF) and dichloromethane were mixed and the solution was cooled to −10° C. in acetone-dry ice bath. Under argon atmosphere, phosphorus oxychloride (40 mL) in dichloromethane was added dropwise to the cool DMF solution, followed by the addition of 10 g of cyclohexanone. The resulting solution was allowed to warm up to room temperature and refluxed for six hours. After cooling to room temperature, the mixture was poured into ice-cold water and stored at 4° C. for twelve hours. About 8g of yellow powder was obtained after filtration. Condensation of the cyclic dialdehyde with the indole intermediate is carried out as described in Example 1. Further functionalization of the dye with bis isopropylidene acetal protected monosaccharide was accomplished by the method described in the literature (J. H. Flanagan, et al., Near infrared heavy-atom-modified fluorescent dyes for base-calling in DNA-sequencing application using temporal discrimination. Anal. Chem., 1998, 70(13), 2676-2684).
EXAMPLE 8
[0080] Synthesis of Bis(ethylcarboxymethyl)indocyanine Dye (FIG. 5)
[0081] These dyes are prepared as described in Example 7. These dyes absorb in the infrared region. The typical example shown in FIG. 5 has an estimated absorption maximum at 1036 nm.
EXAMPLE 9
[0082] Synthesis of Peptides
[0083] The procedure described below is for the synthesis of Octreotate. The amino acid sequence of Octreotate is: D-Phe-Cys′-Tyr-D-Trp-Lys-Thr-Cys′-Thr (SEQ ID NO:1), wherein Cys′ indicates the presence of an intramolecular disulfide bond between two cysteine amino acids. Other peptides of this invention were prepared by a similar procedure with slight modifications in some cases.
[0084] The octapeptide was prepared by an automated fluorenylmethoxycarbonyl (Fmoc) solid phase peptide synthesis using a commercial peptide synthesizer from Applied Biosystems (Model 432A SYNERGY Peptide Synthesizer). The first peptide cartridge contained Wang resin pre-loaded with Fmoc-Thr on 25-μmole scale. Subsequent cartridges contained Fmoc-protected amino acids with side chain protecting groups for the following amino acids: Cys(Acm), Thr(t-Bu), Lys(Boc), Trp(Boc) and Tyr(t-Bu). The amino acid cartridges were placed on the peptide synthesizer and the product was synthesized from the C- to the N-terminal position. The coupling reaction was carried out with 75 μmoles of the protected amino acids in the presence of 2-(1H-benzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate (HBTU)/N-hydroxybenzotriazole (HOBt). The Fmoc protecting group was removed with 20% piperidine in dimethylformamide. After the synthesis was complete, the thiol group was cyclized with thallium trifluoroacetate and the product was cleaved from the solid support with a cleavage mixture containing trifluoroacetic acid (85%):water (5%):phenol (5%):thioanisole (5%) for 6 hours. The peptide was precipitated with t-butyl methyl ether and lyophilized with water:acetonitrile (2:3) mixture. The peptide was purified by HPLC and analyzed with LC/MS.
[0085] Octreotide, D-Phe-Cys′-Tyr-D-Trp-Lys-Thr-Cys′-Thr-OH (SEQ ID NO:2), wherein Cys′ indicates the presence of an intramolecular disulfide bond between two cysteine amino acids, was prepared by the same procedure.
[0086] Bombesin analogs were prepared by the same procedure except that cyclization with thallium trifluoroacetate was not needed. Side-chain deprotection and cleavage from the resin was carried out with 50 μL each of ethanedithiol, thioanisole and water, and 850 μL of trifluoroacetic acid. Two analogues were prepared: Gly-Ser-Gly-Gln-Trp-Ala-Val-Gly-His-Leu-Met-NH 2 (SEQ ID NO:3) and Gly-Asp-Gly-Gln-Trp-Ala-Val-Gly-His-Leu-Met-NH 2 (SEQ ID NO:4).
[0087] Cholecystokinin octapeptide analogs were prepared as described for Octreotate without the cyclization step. Three analogs were prepared: Asp-Tyr-Met-Gly-Trp-Met-Asp-Phe-NH 2 (SEQ ID NO:5); Asp-Tyr-Nle-Gly-Trp-Nle-Asp-Phe-NH 2 (SEQ ID NO:6); and D-Asp-Tyr-Nle-Gly-Trp-Nle-Asp-Phe-NH 2 (SEQ ID NO:7) wherein Nle is norleucine.
[0088] A neurotensin analog, D-Lys-Pro-Arg-Arg-Pro-Tyr-Ile-Leu (SEQ ID NO:8), was prepared as described for Octreotate without the cyclization step.
EXAMPLE 10
[0089] Synthesis of Peptide-dye Conjugates (FIG. 6)
[0090] The method described below is for the synthesis of Octreotate-cyanine dye conjugates, but a similar procedure is used for the synthesis of other peptide-dye conjugates.
[0091] Octreotate was prepared as described in Example 9 but the peptide was not cleaved from the solid support and the N-terminal Fmoc group of Phe was retained. The thiol group was cyclized with thallium trifluoroacetate and the Phe was deprotected to liberate the free amine. Bisethylcarboxymethylindocyanine dye (53 mg, 75 μmoles) was added to an activation reagent consisting of a 0.2 M solution of HBTU/HOBt in DMSO (375 μL), and 0.2 M solution of diisopropylethylamine in DMSO (375 μL). The activation was complete in about 30 minutes and the resin-bound peptide (25 μmoles) was added to the dye. The coupling reaction was carried out at room temperature for three hours. The mixture was filtered and the solid residue was washed with DMF, acetonitrile and THF. After drying the green residue, the peptide was cleaved from the resin and the side chain protecting groups were removed with a mixture of 85% trifluoroacetic acid, 2.5% water, 2.5% thioanisole and 2.5% phenol. The resin was filtered and cold t-butyl methyl ether (MTBE) was used to precipitate the dye-peptide conjugate, which was dissolved in acetonitrile:water (2:3) mixture and lyophilized. The product was purified by HPLC to give the monoOctreotate-Bisethylcarboxymethylindocyanine dye (Cytate 1, 80%) and the bisOctreotate-Bisethylcarboxymethylindocyanine dye (Cytate 2, 20%). The monoOctreotate conjugate is obtained almost exclusively (>95%) over the bis conjugate by reducing the reaction time to two hours. However, this also leads to incomplete reaction, and the free Octreotate must be carefully separated from the dye conjugate in order to avoid saturation of the receptors by the non-dye conjugated peptide.
[0092] Octreotate-bispentylcarboxymethylindocyanine dye was prepared as described above with some modifications. Bispentylcarboxymethylindocyanine dye (60 mg, 75 μmoles) was added to an activation reagent consisting of a 0.2 M solution of HBTU/HOBt in DMSO (400 μL), and 0.2 M solution of diisopropylethylamine in DMSO (400 μL). The activation was complete in about 30 minutes and the resin-bound peptide (25 μmoles) was added to the dye. The reaction was carried out at room temperature for three hours. The mixture was filtered and the solid residue was washed with DMF, acetonitrile and THF. After drying the green residue, the peptide was cleaved from the resin and the side chain protecting groups were removed with a mixture of 85% trifluoroacetic acid, 2.5% water, 2.5% thioanisole and 2.5% phenol. The resin was filtered and cold t-butyl methyl ether (MTBE) was used to precipitate the dye-peptide conjugate, which was dissolved in an acetonitrile:water (2:3) mixture and lyophilized. The product was purified by HPLC to give Octreotate-1,1,2-trimethyl-[1H]-benz[e]indole propanoic acid conjugate (10%), monoOctreotate-bispentylcarboxymethylindocyanine dye (Cytate 3, 60%) and bisOctreotate-bispentylcarboxymethylindocyanine dye (Cytate 4, 30%).
EXAMPLE 11
[0093] Formulation of Peptide-dye Conjugates in Dimethyl Sulfoxide (DMSO)
[0094] The dye-peptide conjugates are sparingly soluble in water and require the addition of solubilizing agents or co-solvents. Addition of 1-20% aqueous ethanol to the conjugates partially quenched the fluorescence intensity in vitro and the fluorescence was completely quenched in vivo (the conjugate was not detected by the charged coupled device (CCD) camera). Addition of 1-50% of DMSO either re-established or increased the fluorescence intensity of the conjugates in vitro and in vivo. The dye fluorescence remained intense for over one week. The DMSO formulations were well tolerated by experimental animals used for this invention.
EXAMPLE 12
[0095] Imaging of Pancreatic Ductal Adenocarcinoma (DSL 6A) with Indocyanine Green (ICG)
[0096] A non-invasive in vivo fluorescence imaging apparatus was employed to assess the efficacy of contrast agents developed for tumor detection in animal models. A LaserMax Inc. laser diode of nominal wavelength 780 nm and nominal power of 40 mW was used. The detector was a Princeton Instruments model RTE/CCD-1317-K/2 CCD camera with a Rodenstock 10 mm F2 lens (stock #542.032.002.20) attached. An 830 nm interference lens (CVI Laser Corp., part # F10-830-4-2) was mounted in front of the CCD input lens such that only emitted fluorescent light from the contrast agent was imaged. Typically, an image of the animal was taken pre-injection of contrast agent. This image was subsequently subtracted (pixel by pixel) from the post injection images. However, the background subtraction was never done once the animal had been removed from the sample area and returned at a later time for images taken several hours post injection.
[0097] DSL 6A tumors were induced in male Lewis rats in the left flank area by the introduction of material from a solid (donor) implant and the tumors were palpable in approximately 14 days. The animals were anesthetized with xylazine; ketamine; acepromazine 1.5:1.5:0.5 at 0.8 mL/kg via intramuscular injection. The area of the tumor (left flank) was shaved to expose tumor and surrounding surface area. A 21 gauge butterfly equipped with a stopcock and two syringes containing heparinized saline was placed into the later tail vein of the rat. Patency of the vein was checked prior to administration of the ICG via the butterfly apparatus. Each animal received 500 mL of a 0.42 mg/mL solution of ICG in water.
[0098] FIGS. 7 A-B are tumor images of two minutes (FIG. 7A) and 30 minutes (FIG. 7B) post bolus injection of a 0.5 ml aqueous solution of ICG (5.4 μm). Tetracarboxylic acid cyanine dyes were synthesized as shown in FIG. 2, with A=CH 2 or CH 2 OCH 2 ; R 1 =R 2 =H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2).
[0099] The Figures are false color images of fluorescent intensity measured at the indicated times, with images constrained to the tumor and a small surrounding area. As is shown, the dye intensity in the tumor is considerably diminished 30 minutes post-ICG injection.
EXAMPLE 13
[0100] Imaging of Prostatic Carcinoma (R3327-H) with Indocyanine Green (ICG)
[0101] The imaging apparatus and the procedure used are described as in Example 12. Prostrate tumors (Dunning R3327-H) were induced in young male Copenhagen rats in the left flank area from a solid implant. These tumors grow very slowly and palpable masses were present 4-5 months post implant. FIGS. 7 C-D are images of a rat with an induced prostatic carcinoma tumor (R3327-H) imaged at two minutes (FIG. 7C) and minutes (FIG. 7D) post injection.
[0102] The Figures are false color images of fluorescent intensity measured at the indicated times, with images constrained to the tumor and a small surrounding area. As is shown, the dye intensity in the tumor is considerably diminished 30 minutes post-ICG injection.
EXAMPLE 14
[0103] Imaging of Rat Pancreatic Acinar Carcinoma (CA20948) with Indocyanine Green (ICG)
[0104] The imaging apparatus and the procedure used are described in Example 12. Rat pancreatic acinar carcinoma expressing the SST-2 receptor (CA20948) was induced by solid implant technique in the left flank area, and palpable masses were detected nine days post implant. The images obtained at 2 and 30 minutes post injection are shown in FIG. 7E-F. FIGS. 7 E-F are images of a rat with an induced pancreatic acinar carcinoma (CA20948) expressing the SST-2 receptor imaged at two minutes (FIG. 7E) and 30 minutes (FIG. 7F) post injection.
[0105] The Figures are false color images of fluorescent intensity measured at the indicated times, with images constrained to the tumor and a small surrounding area. As is shown, the dye intensity in the tumor is considerably diminished and almost absent 30 minutes post-ICG injection.
EXAMPLE 15
[0106] Imaging of Rat Pancreatic Acinar Carcinoma (CA20948) with Cytate 1
[0107] The imaging apparatus and the procedure used are described in Example 12 except that each animal received 500 μl of a 1.0 mg/mL solution of Cytate 1 solution of 25% dimethylsulfoxide in water.
[0108] Rat pancreatic acinar carcinoma expressing the SST-2 receptor (CA20948) were induced by solid implant technique in the left flank area, and palpable masses were detected 24 days post implant. Images were obtained at various times post injection. Uptake into the tumor was seen at two minutes but was not maximal until about five minutes.
[0109] FIGS. 8 A-B show a comparison of the uptake of ICG and Cytate 1 at 45 minutes in rats with the CA20948 tumor cell line. By 45 minutes the ICG has mostly cleared (FIG. 8A) whereas the Cytate 1 is still quite intense (FIG. 8B). This dye fluorescence remained intense in the tumor for several hours post-injection.
EXAMPLE 16
[0110] Imaging of Rat Pancreatic Acinar Carcinoma(CA20948) with Cytate 1 Compared with Imaging with Indocyanine Green
[0111] Using indocyanine green (ICG), three different tumor lines were imaged optically using a CCD camera apparatus. Two of the lines, DSL 6/A (pancreatic) and Dunning R3327H (prostate) indicated slow perfusion of the agent over time into the tumor and reasonable images were obtained for each. The third line, CA20948 (pancreatic), indicated only a slight but transient perfusion that was absent after only 30 minutes post injection. This indicated no non-specific localization of ICG into this line compared to the other two tumor lines, suggesting a different vascular architecture for this type of tumor (see FIGS. 7 A-F). The first two tumor lines (DSL 6/A and R3327H) are not as highly vascularized as CA20948 which is also rich in somatostatin (SST-2) receptors. Consequently, the detection and retention of a dye in this tumor model is a good index of receptor-mediated specificity.
[0112] Octreotate is known to target somatostatin (SST-2) receptors, hence, cyano-Octreotates (Cytate 1 and Cytate 2) was prepared. Cytate 1 was evaluated in the CA20948 Lewis rat model. Using the CCD camera apparatus, localization of this dye was observed in the tumor (indicated by arrow) at 45 minutes post injection (FIG. 9A). At 27 hours post injection, the animal was again imaged (FIG. 9B). Tumor visualization was easily observed (indicated by arrow)showing specificity of this agent for the SST-2 receptors present in the CA20948 tumor line.
[0113] Individual organs were removed at about 24 hours post Cytate 1 administration and imaged. As shown in FIG. 10, high uptake of Cytate 1 was observed in the pancreas, adrenals and tumor tissue, while heart, muscle, spleen and liver indicated significantly lower uptake. These data correlate well with radiolabeled Octreotate in the same model system (M. de Jong, et al. Cancer Res. 1998, 58, 437-441).
EXAMPLE 17
[0114] Imaging of Rat Pancreatic Acinar Carcinoma (AR42-J) with Bombesinate
[0115] The AR42-J cell line is derived from exocrine rat pancreatic acinar carcinoma. It can be grown in continuous culture or maintained in vivo in athymic nude mice, SCID mice, or in Lewis rats. This cell line is particularly attractive for in vitro receptor assays, as it is known to express a variety of hormone receptors including cholecystokinin (CCK), epidermal growth factor (EGF), pituitary adenylate cyclase activating peptide (PACAP), somatostatin (SST-2) and bombesin.
[0116] In this model, male Lewis rats were implanted with solid tumor material in a similar manner as described for the CA20948 rat model. Palpable masses were present seven days post implant, and imaging studies were conducted on animals at 10-12 days post implant when the mass had achieved about 2-2.5 g.
[0117] [0117]FIG. 11 is an image of bombesinate in an AR42-J tumor-bearing rat, as described in Example 16, at 22 hours post injection of bombesinate. As shown in FIG. 11, specific localization of the bioconjugate in the tumor (indicated by arrow) was observed.
EXAMPLE 18
[0118] Monitoring of the Blood Clearance Profile of Peptide-dye Conjugates
[0119] A laser of appropriate wavelength for excitation of the dye chromophore was directed into one end of a fiber optic bundle and the other end was positioned a few millimeters from the ear of a rat. A second fiber optic bundle was also positioned near the same ear to detect the emitted fluorescent light and the other end was directed into the optics and electronics for data collection. An interference filter (IF) in the collection optics train was used to select emitted fluorescent light of the appropriate wavelength for the dye chromophore.
[0120] Sprague-Dawley or Fischer 344 rats were used in these studies. The animals were anesthetized with urethane administered via intraperitoneal injection at a dose of 1.35 g/kg body weight. After the animals had achieved the desired plane of anesthesia, a 21 gauge butterfly with 12″ tubing was placed in the lateral tail vein of each animal and flushed with heparinized saline. The animals were placed onto a heating pad and kept warm throughout the entire study. The lobe of the left ear was affixed to a glass microscope slide to reduce movement and vibration.
[0121] Incident laser light delivered from the fiber optic was centered on the affixed ear. Data acquisition was then initiated, and a background reading of fluorescence was obtained prior to administration of the test agent. For Cytates 1 or 2, the peptide-dye conjugate was administered to the animal through a bolus injection, typically 0.5 to 2.0 ml, in the lateral tail vein. This procedure was repeated with several dye-peptide conjugates in normal and tumor bearing rats. Representative profiles as a method to monitor blood clearance of the peptide-dye conjugate in normal and tumor bearing animals are shown in FIGS. 12 - 16 . The data were analyzed using a standard sigma plot software program for a one compartment model.
[0122] In rats treated with Cytates 1 or 2, the fluorescence signal rapidly increased to a peak value. The signal then decayed as a function of time as the conjugate cleared from the blood stream. FIG. 12 shows the clearance profile of Cytate 1 from the blood of a normal rat monitored at 830 nm after excitation at 780 nm. FIG. 13 shows the clearance profile of Cytate 1 from the blood of a pancreatic tumor (CA20948)-bearing rat also monitored an 830 nm after excitation at 780 nm.
[0123] [0123]FIG. 14 shows the clearance profile of Cytate 2 from the blood of a normal rat, and FIG. 15 shows the clearance profile of Cytate 2 from the blood of a pancreatic tumor (CA20948)-bearing rat, monitored at 830 nm after excitation at 780 nm.
[0124] [0124]FIG. 16 shows the clearance profile of Cytate 4 from the blood of a normal rat, monitored at 830 nm after excitation at 780 nm.
[0125] It should be understood that the embodiments of the present invention shown and described in the specification are only specific embodiments of inventors who are skilled in the art and are not limiting in any way. Therefore, various changes, modifications, or alterations to those embodiments may be made or resorted to without departing from the spirit of the invention in the scope of the following claims. The references cited are expressly incorporated by reference herein in their entirety. | Cyanine dye bioconjugates useful for diagnostic imaging and therapy are disclosed. The conjugates include several cyanine dyes with a variety of bis- and tetrakis (carboxylic acid) homologes. The compounds may be conjugated to bioactive peptides, carbohydrates, hormones, drugs, or other bioactive agents. The small size of the compounds allows more favorable delivery to tumor cells as compared to larger molecular weight imaging agents. The various dyes are useful over the range of 350 to 1,300 nm, the exact range being dependent upon the particular dye. The use of dimethylsulfoxide helps to maintain the fluorescence of the compounds. The inventive compounds are useful for diagnostic imaging and therapy, in endoscopic applications for the detection of tumors and other abnormalities, for localized therapy, for photoacoustic tumor imaging, detection and therapy, and for sonofluorescence tumor imaging, detection and therapy. | 0 |
BACKGROUND OF THE INVENTION
1. Related Applications
This application is related to co-pending applications which describe related apparatii and methods for detecting vapors in an automotive steering wheel structure; including an application entitled, “Steering Wheel Vapor Collection and Sensing System Using Suction,” which was filed on Jul. 26, 2004 as Ser. No. 10/899,826; and an application entitled “Steering Wheel Vapor Collection and Sensing System Using a Chemical Element,” which was filed on Aug. 12, 2004 as Ser. No. 10/917,694.
2. Incorporation by Reference
Applicant hereby incorporates herein by reference, the U.S. patents and U.S. patent applications, described in the Description of Related Art section of this application; specifically by document number: 20030087452; U.S. Pat. Nos. 4,090,078; 4,277,251; 4,363,635; 4,649,027; 4,749,553; 4,849,180; 4,905,498; 5,055,268; 5,220,919; 5,376,555; 5,743,349; 6,075,444; 6,097,480; 6,183,418; 6,620,108, 6,031,233 and 4,594,509.
3. Field of the Invention
This invention relates generally to light spectroscopy and especially to the detection of trace amounts of an alcohol containing substance carried by perspiration such as a person's skin surfaces. This invention is related to analyzers used by law enforcement agencies where the breath of a driver is subject to analysis; and more particularly to a steering wheel mounted structure for collection and detection of such vapors through the use of infrared spectrometry.
4. Background Details and Description of Related Art
Plastics and many other materials can be identified by their infrared (IR) reflectance or transmission spectrum. Each type—nylon, polyethylene, etc.—has its own IR characteristic spectrum. If a generally constant-intensity IR beam incident on a plastic is scanned through a range of wavelengths, and the intensity of the reflected or transmitted light is measured as a function of the wavelength, then the measured spectrum can be used to identify the type of plastic.
In addition, mixtures of plastics or other materials can be quantitatively analyzed. The reflectance or transmission spectrum of a sample can show that it is, for example, 50% nylon and 50% polyethylene. The proportion of octane in a sample of gasoline can be measured, or the amount of fat in a chocolate bar. Likewise, trace amounts of ethanol can be detected as present on the hands or as liberated in the sweat on ones hands.
Several types of IR spectrometers are known. Some use a diffraction grating or FTIR technology; these are bulky, delicate, and slow. They are not suited to rapid identification of substances or for rugged use.
Another type uses an acousto-optical tunable filter (AOTF) such as that disclosed in U.S. Pat. No. 5,120,961 to Levin et al, U.S. Pat. No. 4,883,963 to Kemeny et al, and U.S. Pat. No. 4,052,121 to Chang, the entire contents of which patents are fully incorporated herein by reference. The acousto-optic tunable filter (AOTF) is based on a birefringent crystal, such as a crystal of TeO.sub.2 (tellurium dioxide) which acts as an electronically tunable narrowband filter, in which diffraction results from an acoustic pressure wave in the crystal.
If an acoustic wave traverses the crystal, the compression or pressure inside the crystal varies as the wave passes, causing a periodic variation in the refractive index. As crystal compression varies, so does the birefringence of a beam of unpolarized visible or IR light that passes through the crystal in a direction normal to its entry and exit faces. When sound having a certain acoustic wavelength is present in the crystal, the crystal acts as an optical filter passing that infrared light having a wavelength proportional to the acoustic wavelength. Because the birefringent crystal acts as a frequency-selective narrowband optical filter, and sound of any acoustic wavelength can be passed through the crystal, any desired visible or IR wavelength can be selected at will, just by varying the frequency of an acoustic driver.
The acoustic driver is a second crystal of the piezo-electric type (quartz or lithium niobate, LiNbo), which is an acoustic transducer. Such a piezo crystal changes its size when subjected to an RF field.
Birefringent TeO.sub.2 bonded to piezo-electric LiNo, in which the LiNo is subjected to a sinusoidally-varying AC voltage applied across the face parallel to the birefringent crystal, will act as a swept-frequency optical filter. When the AC voltage impressed across the piezo crystal is at high radio-frequencies (RF) of 20–100 MHz, the acoustic wavelength corresponds to infrared (IR) light wavelengths. (One MHz is one million cycles per second.) The impressed voltage may be obtained from digital synthesizer, controlled by a software algorithm which determines the frequencies generated, and which can sequentially scan or hop in a random access fashion.
Broad-spectrum white light (from a halogen lamp, for example) which shines through the crystal (parallel to the junction between the birefringent and piezo-crystals) will emerge as a beam having one optical frequency corresponding to the acoustic frequency of sound in the piezo crystal. Typical IR wavelengths selected by the AOTF filter are from 1–3 microns (near infrared) or from 2–5 microns (mid-infrared).
The tuned infrared beam can then be either reflected from, or transmitted through, a sample to determine the spectrum and identification of the sample. To identify the sample of plastic or other material, the swept-frequency beam of light is made to shine onto a surface of the undetermined material, which will reflect different proportions of the light falling onto it at each of the various frequencies. A photodetector can be used to pick up the reflected light and turn it into an electrical signal. Electronic circuits can then plot the pattern of the material's reflectance of IR or light frequency, and use that pattern to identify the material by matching the pattern with known patterns corresponding to various materials.
IR spectrometers can measure the proportion of a compound in a sample, by calibrating the circuitry to recognize samples having various percentages of compounds. The percentage can also be calculated according to Beer's law.
Compared to other spectrometer instruments such as diffraction gratings and the FTIR, the AOTF spectrometer has the advantages of no moving parts, high speed wavelength tuning, and small size. However, previous AOTF spectrometers have consisted of a fairly bulky and heavy electronics and optical modules, so that its use is limited to the laboratory. The present spectrometer overcomes these problems and provides compact, light weight solutions ideal for the applications described herein and use within a steering wheel housing.
The following references describe the means by which substances such as ethanol are detected and measured presently.
Levin, et al, U.S. Pat. No. 6,031,233 discloses a handheld device for infrared reflectance measurements of samples for identification of the sample materials in a self-contained portable unit built into a handheld housing. The housing includes a window and optics on a bench adjacent the window, so that the optics will be aligned with the sample when the device is placed directly against the sample. The optics include a broad-band IR light source t (ordinary lamp) shining onto an acousto-optic tunable filter (AOTF), which passes narrow-band IR light with a swept frequency; a lens focusing the IR through the window onto the sample; and a reflectance detector aligned with the window of the housing to pick up reflected light. A computer, which may be mounted in the housing, compares the detected reflectance spectrum with stored sample data spectra, and identifies the material or the components of the material and their proportions. Inclusion of all the parts inside the housing allows the device to be portable; this is made possible by the alignment of the lamp, AOTF filter, lens, window, and detector, which has high optical efficiency, and by elimination of optical fibers.
Simon, et al, U.S. Pat. No. 4,594,509 discloses an infrared spectrometer comprising a first optical means for focusing a beam of light in a point-shaped area of a sample ( 19 ), second optical means for focusing upon a detector ( 26 ) the light emitted by the sample, and third optical means permitting the visual observation of the point-shaped area ( 19 ). The second optical means of this arrangement are so designed that they pick up the light reflected by the point-shaped area ( 19 ). The arrangement of the invention permits measurements to be performed on extremely small areas and even on samples which are not or hardly pervious to light in the infrared range.
Ratogi, et al. 20030087452, discloses a method of making a bismuth molybdate precursor solution using a metallorganic decomposition (MOD) process consisting of the formation of a precursor sol of hexanoates of Bismuth (Bi) and Molybdenum (Mo). The precursor solution is used to make thin film of Bismuth molybdate by spin coating and spray pyrolysis. The bismuth molybdate films have the useful alpha and gamma phases having high sensitivity to ethanol gas, the detection of the ethanol gas is based upon the change of electrical conductivity of a thick film of the semiconductor oxide sensing element resulting from the ethanol gas in an oxygen-containing atmosphere. When the drying is effected by spray pyrolysis, quite thick films with high adhesion have been produced over different substrates, including quartz. The thin film of the present invention made by spray pyrolysis has a very fast response to ethanol detection eg typically 5 seconds.
Heim, U.S. Pat. No. 4,090,078 describes a method for determining the alcohol content in the exhaling respiratory air using an alcohol measuring instrument and measuring the alcohol content when the exhaling air transmits the determined value of the alcohol concentration. This determined value of alcohol concentration occurs when the time variation related to the height of the alcohol signal is below a predetermined threshold value and the velocity of flow of the exhaling air is above a given value and is maintained without interruption for a given time. The apparatus includes an infrared measuring instrument which is connected into the respiratory air current and measures the alcohol concentration of the exhaling air. This value is applied to an indicator through a linear gate when an AND-gate is triggered by threshold comparators and a timing element activated by a threshold comparator.
Leichnitz, U.S. Pat. No. 4,277,251 describes a method of determining the alcohol content of air exhaled by a person using a flow through testing tube having an alcohol indicating material therein and a sampling tube to which the air is directed which has a material therein for retaining the alcohol of the breathing air and also using a suction pump comprises cooling the sampling tube, passing the exhaled air through the cooled sampling tube, measuring a volume of the air passing through the cooled sampling tube, heating the sampling tube and connecting the suction pump to the sampling tube to suck flushing air through the heated tube and then through the testing tube. The sampling tube advantageously contains a silica gel to retain the alcohol therein. The volume measuring device may be a measuring bag.
Hutson, U.S. Pat. No. 4,363,635 describes a method and apparatus for discriminating between alcohol and acetone in a breath sample and accurately measuring the alcohol level when acetone is present in the sample. The breath sample is measured with two different types of detectors and their outputs compared. One detector uses the principles of infrared (IR) absorption, the other detector is a semiconductor, commonly called a Taguci cell, or its equivalent. Automatic correction is provided for variations in sensitivity of the semiconductor.
Talbot, U.S. Pat. No. 4,649,027 describes a battery-operated portable breath tester. The breath tester includes a housing which defines a sleeve for receiving a wand. The wand defines an internal sample chamber, with a lamp at one end for providing infrared energy and a detector at an opposite end for receiving the infrared energy after it has passed through the sample to be tested. The wand defines opening extending from the internal sample chamber to the outside of the wand. The wand has an external shape providing a snug fit within the sleeve. As the wand is moved within the sleeve, gas is purged from the wand. The wand is connected to the housing by means of an electrical coil. The housing encloses a digital voltmeter including a digital display for providing a test readout. The digital voltmeter includes an oscillator which is coupled through a frequency divider and a transistor switch to the lamp. The lamp is switched on and off in accordance with the frequency output of the frequency divider to modulate the infrared energy emitted from the lamp at a selected frequency. A voltage regulator is connected to the lamp, and the lamp and voltage regulator are located in heat-exchange relationship with the sample chamber. This aids in raising the temperature of the sample chamber during testing in order to alleviate condensation.
Lopez, U.S. Pat. No. 4,749,553 describes a breath alcohol detector for measuring and compensating for distance between the mouth of the individual exhaling breath into the ambient air and the detector, the atmospheric pressure, and the temperature. Blood alcohol content information is calculated using these compensation factors and a signal obtained from an electrochemical fuel cell which is indicative of the amount of alcohol or other gas contained in the sample. The detector also includes a reciprocally acting electromagnetically energized motor which drives a diaphragm pump to draw the sample into the electrochemical fuel cell.
Fukui, U.S. Pat. No. 4,849,180 describes an alcohol selective gas sensor including a detecting electrode and a semiconductor detecting element in contact with the detecting electrode, the semiconductor detecting element comprising tin oxide (SnO 2 ) and a metal oxide of at least one of alkaline earth metals (Be, Mg, Ca, Sr, Ba) carried by the tin oxide, the metal oxide being contained in an amount of about 0.5 mol % or above.
O'Donnell et al., U.S. Pat. No. 4,905,498 describes a gaseous detection system for detecting the existence of a certain gas and further the detection of a certain level or percentage of that certain gas within a certain environment. An example is use of the gas detection system in a motor vehicle to aid in determining when a driver of the motor vehicle may be driving under the influence of alcohol, and for providing an appropriate warning signal that may be viewed from the exterior of the motor vehicle. The system includes a sensor unit for sensing ethanol in the atmospheric contents of the motor vehicle's interior, for example, a unit for providing an actuation signal in response to the sensing unit, and a signal unit that generates a signal which can be utilized for many purposes, for example, causing at least some of the exterior lights on the motor vehicle to alternately flash on and off in a substantially non-standard pattern. The sensing unit may also be coupled with a digital read-out device or the like to indicate the amount of blood alcohol content of a person for evidentiary or like purposes.
Martin, U.S. Pat. No. 5,055,268 describes an air-borne chemical sensor system including a motor and impeller to draw an air sample into a housing containing a sensor which will provide a signal for display related to the amount of a particular air-borne chemical in a given air sample. The system is controllable by different duration activation of a single activating switch which can further control a secondary function, such as a flashlight.
Phillips, U.S. Pat. No. 5,220,919 describes a gaseous detection system for detecting the existence of a certain gas and further the detection of a certain level or percentage of that certain gas within a certain environment. An example is use of the gas detection system in a motor vehicle to aid in determining when a driver of the motor vehicle may be driving under the influence of alcohol, and for providing an appropriate warning signal that may be viewed from the exterior of the motor vehicle. The system includes a sensor unit for sensing ethanol in the atmospheric contents of the motor vehicle's interior, for example, a unit for providing an actuation signal in response to the sensing unit, and a signal unit that generates a signal which can be utilized for many purposes, for example, causing at least some of the exterior lights on the motor vehicle to alternately flash on and off in a substantially non-standard pattern. The sensing unit may also be coupled with a digital read-out device or the like to indicate the amount of blood alcohol content of a person for evidentiary or like purposes.
Forrester et al., U.S. Pat. No. 5,376,555 describes a method and infrared sensing device for determining the concentration of alveolar alcohol in a breath sample exhaled by a subject into an infrared sensing device. The presence of alcohol from the upper respiratory tract of the subject is detected by continuously monitoring alcohol and carbon dioxide, normalizing alcohol values with respect to carbon dioxide, calculating a difference between normalized alcohol concentration and carbon dioxide concentration over time, integrating (summing) the difference, and comparing the integrated difference with a threshold. This technique accurately and consistently detects the presence of mouth alcohol in the sample before the presence of carbon dioxide which originates in deep lung breath.
Steinberg, U.S. Pat. No. 5,743,349 describes a vehicle ignition interlock system including a non-invasive reader of a person's blood-alcohol concentration in combination with ignition interlock circuitry that prevents operation of a vehicle by an intoxicated person. The non-invasive blood-alcohol concentration reader, termed alcoh-meter, utilizes optical spectroscopic electromagnetic radiation technology to determine the alcohol levels in the blood. The alcoh-meter is preferably a dash mounted sensor for receiving a person's finger and absorbing incident light from a multiple wavelength light source and causing a light absorption reading to be generated based on the person's blood alcohol concentration in the finger tissue. After registering a reading, the results are compared electronically against a table of impaired/non-impaired levels of blood alcohol concentration. The impaired/non-impaired results are communicated to interlock circuitry that either enables, or disables start-up of the vehicle. If an impaired status is determined, the results are displayed instructing the operator to wait, or find a non-impaired operator.
Sohèege et al., U.S. Pat. No. 6,075,444 describes an arrangement for blocking the operation by an intoxicated operator of a machine or a motor vehicle. The arrangement has a measuring apparatus which determines the blood alcohol content of the operator and an evaluation unit connected to the machine or motor vehicle. The evaluation unit receives measurement data supplied by the measurement apparatus and enables the machine or motor vehicle when the measurement data satisfies at least one predetermined condition. The arrangement is improved in that the sobriety of the operator is recognized before the starting operation of the machine or motor vehicle without it being necessary to supply a breath sample. The measuring apparatus includes a gas sensor which is a sensor for measuring the blood alcohol content via permeation through the skin of the operator. The measuring apparatus is configured so that it can be worn by the operator preferably on the leg or arm.
Kaplan, U.S. Pat. No. 6,097,480 describes a vehicle interlock system which utilizes non-invasive, optically based methods for detecting and measuring levels of certain target chemical substances in the blood or tissues of a user in preventing operation of the vehicle by persons exhibiting higher (or lower) than prescribed levels of such chemicals. The system of the present invention is not limited to simply measuring blood alcohol levels as are presently available breathalizer-based interlock systems, but lends itself to use in detecting unacceptable systemic levels of virtually any chemical for which the system if programmed to measure. In addition, the present system includes components for positively identifying, and during the course of vehicle operation, re-identifying the intended user and alcohol or drug user testee.
Kuennecke, U.S. Pat No. 6,183,418 describes the process for detection and for quantitative determination of substances emitted or perspired through the skin is derived from flow diffusion analysis. The measuring system conceived for this purpose uses a diffusion half cell through which an acceptor medium flows and which is closed by a membrane. For the duration of the measurement, the membrane is brought into contact with the skin or a closed gas volume formed over the skin. With the process and the related measuring system, the blood alcohol level can be determined with a good degree of precision indirectly via the quantity of (gaseous) ethanol emitted through the skin.
Duval, U.S. Pat. No. 6,620,108 describes an apparatus and method for assuring that a machine operator is not under the influence of a chemical, comprising a first sensor positioned proximally to the machine operator and adapted for measuring a vapor concentration proximal thereto, a second sensor positioned distally from the machine operator and adapted for measuring the vapor concentration distally from the operator, a device for comparing the proximal and distal vapor concentrations, and an automated remediating element responsive to the comparing device when the ratio of the first and the second vapor concentrations are within a specified range.
Our prior art search with abstracts described above primarily teaches the use of analyzing vapors produced in the exhalant of an individual. Thus, the prior art shows several solutions to the collection and analysis of minute partial pressures of vapors. However, the prior art fails to teach a simple system that can avoid the use of deliberate breath analysis and yet be inexpensive by avoiding the very high sensitivity required of room air analyzers. The present solution employs a steering wheel having an integral infrared spectrometer which is able to detect alcohol in perspiration on a users hands, i.e., excreted through the skin; analyze the vapors and produce a control signal. This enablement allows automatic monitoring and the initiation of remedial actions when necessary for the safety of the individual and the public at large. The present invention fulfills these needs and provides further related advantages as described in the following summary.
SUMMARY OF THE INVENTION
Data has been collected on the number of accidents and accident related deaths on U.S. highways each year that are, at least in part, related to alcohol or other substances within the blood stream of drivers. This data shows that it would be wise to take steps to prevent motorists from driving when they are under the influence of such substances. One solution to this problem is to install a device in existing and new automobiles, and other types of vehicles that will monitor and possibly prevent such driving. The present invention teaches certain benefits in construction and use of such devices which give rise to the objectives described below and forms at least a partial solution to this problem.
The invention is a detection system installed into a steering wheel of a vehicle wherein an infrared spectrometer is used to detect ethanol vapors emitted by the driver's hands. Such vapors may also be from the driver's breath, clothing, and other exposed skin areas that come into contact or merely just close proximity to the light source of the spectrometer. It may be used on automobiles, trucks, buses, boats and other vehicles. Such detection may be used to trigger a warning or other action, including shutting down the ignition system of the vehicle. In a best mode preferred embodiment of the present invention, a solid state infrared spectrometer is made an integral part of a steering wheel assembly. The spectrometer is preferably a part of a detection and alarm system built into the vehicle and the spectrometer detector is preferably in communication with other circuitry components of the detection and alarm system by wireless means. Such circuitry may be placed behind a control or dash board of the vehicle, and may be enabled for controlling an ignition circuit of the vehicle. Alternately, the control circuit might control audible or visual devices to inform the driver that he/she is driving dangerously, or might control other devices as deemed necessary to protect the driver, any passengers and the general public.
A primary objective of the present invention is to provide an apparatus and method of use of such apparatus that yields advantages not taught by the prior art.
Another objective is to assure that an embodiment of the invention is capable of integrating vapor detection with a steering wheel assembly.
A further objective is to assure that the vapor of choice is detected by the steering wheel assembly.
A still further objective is to assure that an electrical signal is generated by the spectrometer vapor detector so as to generate an alert signal.
Other features and advantages of the embodiments of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of several possible embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the best mode embodiments of the present invention.
In such drawings:
FIG. 1 is a sectional elevational view of an infrared spectrometer of the invention;
FIG. 2 is a perspective view of a steering wheel and steering column structures showing three possible locations for mounting the spectrometer for aligning its output signal with holes in the steering wheel; and
FIG. 3 is a perspective view of the invention as used in a vehicle.
DETAILED DESCRIPTION OF THE INVENTION
The above described drawing figures illustrate the present invention in two of its preferred, best mode embodiments, which is further defined in detail in the following description. Those having ordinary skill in the art may be able to make alterations and modifications in the present invention without departing from its spirit and scope. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of example and that they should not be taken as limiting the invention as defined in the following.
Here, and in the following claims, “light” refers to all electromagnetic waves that can be produced, detected, or controlled by optical means, and includes infrared (IR), visible light, or ultraviolet (UV) unless otherwise specified; “pyramid detector” means any detector with one or more light-to-electricity converting transducers deployed adjacent to a hole; and “window” means an opening or interruption in an opaque wall that allows a light beam to pass through.
FIG. 1 shows the interior of an AOTF spectrometer according to the Levin et al reference, and which is used to identify an unknown material. The spectrometer is housed in a housing 10 which includes a window 15 . The window 15 is preferably one which is opaque or at least partially opaque to visible light, but transparent to IR. The housing 10 may be made quite small and can easily fit within the central portion of most automobile steering wheel assemblies, as shown in FIG. 2 . The typical steering wheel mounted horn actuator voltage is used to power the spectrometer's circuits for making measurements.
Inside the housing 10 are an optical bench 100 and a single printed circuit board 200 which contains all of the system electronics. A computer 202 for data analysis is built into the device as shown. A remote computer is accessed through the port 232 via conductor wires, or port 232 may be a radio transmitter for wireless communication to a control circuit 60 shown in FIG. 3 .
The optical module consists of several optical components mounted on the bench 100 , which is preferably a solid plate, e.g., formed of aluminum. The optical components include the following elements, provided in a linear relationship: a light source or lamp 110 (a tungsten-halogen lamp, for example); an AOTF crystal and case 120 ; a focusing lens 130 ; and a reflectance detector 140 . The AOTF crystal, preferably including TeO.sub.2 (tellurium dioxide), is about one inch long and one-half inch wide. The AOTF 120 includes a piezo-electric transducer, preferably of LiNo, bonded to one face of the bi-refringent TeO.sub.2 crystal. A small RF power amplifier 124 is mounted in close proximity to the crystal 122 ; it produces about 1 Watt of RF power in the frequency range from 20 to 100 MHz.
The lamp 110 is contained within a parabolic mirror 112 in order to collimate the beam. This beam then passes through the AOTF crystal 120 , and emerges as a tuned, narrow-band infrared beam approximately 8 by 8 mm in size. This beam passes through the lens 130 , which focuses the beam through the window 15 , onto the sample to be analyzed.
At the end of the optical bench is mounted a reflectance detector 140 . This detector may include up to four or even more lead sulfide (PbS) or lead selenide (PbSe) flat detector elements or transducers 145 , each about 10 by 10 mm in size and facing the sample through the window 15 . The detectors are arranged on the inner surface of a 45 degree pyramid or cone. The cone has a hole 143 at the apex for the light beam to pass through. The base of the pyramid faces the sample. Therefore, the infrared beam strikes the sample, and the diffusely reflected light from the sample (indicated by arrows in FIG. 1 ) is detected by the detector elements 145 .
As indicated above, the housing includes the window 15 , which in the preferred embodiment is a transparent element having broad-band IR transmission but little visible transmission; it appears black. The optical properties of the window 15 , like those of the other optical elements, are compensated for automatically when the device is calibrated using a pure white ceramic material.
The small printed circuit board 200 mounted above the optical bench 100 contains all of the system electronics 204 , including: a digitally-controlled frequency synthesizer (used to generate the RF frequencies to tune the AOTF), a detector preamplifier and bias voltage, an A/D converter, and computer interface (e.g., RS-232). In addition, there is an amplitude modulator (and de-modulator) circuit which modulates the RF signal at about 5 kHz for improved signal to noise ratio. The frequency synthesizer is preferably a lower-frequency generator (e.g., up to 50 MHz) driving a doubler; this arrangement uses less power.
As shown in FIG. 2 , the spectrometer described above is mounted within the steering wheel assembly 70 . In one embodiment, the spectrometer housing 10 is mounted for emitting along light path “A” which is aligned with holes 72 in the steering wheel so that the light is able to strike the hand of a driver. In another embodiment, the spectrometer housing 10 is mounted for emitting along light path “B,” again, wherein the path transits holes 72 . In a still further alternative embodiment, the housing 10 is placed for emitting light as reflected from mirror 5 ( FIG. 1 ). Mirror 5 is motor driven to move rapidly over a range of angles thereby reflecting the spectrometer's output light beam to positions shown by “C” in FIG. 2 . Finally, in a final embodiment, the housing 10 is positioned so that the output window 15 is in actual contact or near contact with a hand of the driver, i.e., light path “D.” Holes 72 are placed in the steering wheel 70 and are through holes whereby the output light beam “A,” “B,” “C,” or “D” is able to pass through the steering wheel 70 and strike the hand of a driver, as shown in FIG. 3 . The light that is scattered back toward the spectrometer passes, again, through the holes 72 and is conducted directly, or by mirror 5 to sensors 145 . With respect to the embodiment producing the moving light beam “C,” it may be seen that no matter where the driver places his/her hands, the light beam “C” will strike at least one of them causing a spectrometer reading. The reading is then transmitted, preferably by radio waves, as shown in FIG. 3 , to the alarm circuit 60 which may be placed anywhere within the vehicle. Since the object of this invention is to detect only those spectral lines associated with ethanol, the spectrometer may be miniaturized by dedicating it to only that one task.
The preferred method of the present invention for identifying a material composition of a sample comprises, providing the spectrometer of this invention within the steering wheel assembly with placement as shown in FIG. 2 . Disposing a window of the spectrometer in an exterior position on the steering well assembly, in optical alignment with a hand of a driver of the vehicle or in contact or near contact with a surface of the hand. Projecting a spectral light beam onto the sample and receiving reflected light from the sample at detectors in the spectrometer. The method further includes spectrally analyzing the reflected light for a selected substance such as ethanol alcohol, and upon detection of the substance at a selected magnitude, sending an alarm signal to an alarm circuit.
The enablements described in detail above are considered novel over the prior art of record and are considered critical to the operation of at least one aspect of one best mode embodiment of the instant invention and to the achievement of the above described objectives. The words used in this specification to describe the instant embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification: structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use must be understood as being generic to all possible meanings supported by the specification and by the word or words describing the element.
The definitions of the words or elements of the embodiments of the herein described invention and its related embodiments not described are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the invention and its various embodiments or that a single element may be substituted for two or more elements in a claim.
Changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalents within the scope of the invention and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. The invention and its various embodiments are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted, and also what essentially incorporates the essential idea of the invention.
While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims and it is made clear, here, that the inventor(s) believe that the claimed subject matter is the invention. | A spectrometer for infrared reflectance measurements of samples for identification of the sample materials is built into a steering wheel assembly. The spectrometer includes a window and optics on a bench adjacent the window, so that the optics will be aligned with the sample when the device is placed in optical alignment with or directly against the sample. The optics include a broad-band IR light source (ordinary lamp) shining onto an acousto-optic tunable filter (AOTF), which passes narrow-band IR light with a swept frequency; a lens focusing the IR through the window onto the sample; and a reflectance detector aligned with the window of the spectrometer to pick up reflected light. A computer, which may be mounted in the spectrometer, compares the detected reflectance spectrum with stored sample data spectra, and identifies the material or the components of the material and their proportions. When a control substance is detected an alarm signal is produced. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to locked joints between metal pipes, especially spheroidal-graphite cast-iron pipes.
The joints between such pipes are subjected to separation forces when fluids under pressure are conveyed.
One particularly economical way of locking these joints consists in incorporating, into the seals made of elastomer or other flexible substance, a ring of locking inserts of planar general shape which are contained in radial planes. Where the joints tend to separate, the inserts are braced against appropriate bearing surfaces and thus prevent the pipes from separating. An example of this technique is described in the Assignee's published Patent Application FR-2,679,622.
When the pipes are metallic, it is sometimes necessary, for reasons of safety, to insulate the pipes electrically from each other. Now, the inserts, being metallic, form electrically conducting pathways.
It has been proposed to produce inserts from insulating materials, but this has turned out to lead to expensive and fragile inserts.
It has also been proposed to coat metal inserts with an insulating layer, at least in a region where these inserts bear against the pipes. However, such coatings are in contact with a relatively rough metal surface, are moved frictionally over this surface and are stressed not only in compression but also in shear. As a consequence, they are quickly damaged and removed.
SUMMARY OF THE INVENTION
The object of the invention is to make it possible to ensure, economically, effective and lasting electrical insulation when using seals which include locking inserts.
For this purpose, the subject of the invention is. a locking insert for a seal, of planar general shape, comprising at least two metal parts fixed to each other by means of an electrically insulating junction layer.
Such an insert may include one or more of the following characteristics:
--the junction layer is approximately perpendicular to the thrust axis of the insert;
--the junction layer extends approximately over a cross-section of maximum area of the insert;
--the junction layer consists of a low-creep insulating organic substance simultaneously ensuring the bonding of and the electrical insulation between the two metal parts, the organic substance being unfilled or filled with particles of non-creeping insulating materials;
--the junction layer comprises a fabric, fibrous bed or mat, which is dense and non-creeping, especially made of an inorganic substance, connected on each side to one of the metal parts by means of a bonding layer made of an organic substance;
--the junction layer comprises a non-creeping insulating coating, especially made of an inorganic substance, deposited on one of the metal parts, and a bonding layer, especially made of an organic substance, connecting this coating to the other metal part;
--the junction layer consists of a non-creeping insulating bonding substance, especially of a refractory material such as enamel, connected directly to the facing surfaces of the two metal parts;
--the junction surfaces have, in cross-section, at least in one direction, a non-rectilinear profile, especially a U-shaped, V-shaped or sinuous profile;
--the junction surfaces have a planar or pseudo-planar profile interrupted by facing recesses which are intended to house an insulating member for the relative positioning of the metal parts.
The subjects of the invention are also:
--a seal made of a flexible substance into which is incorporated at least one locking insert as defined hereinabove;
--a method of manufacturing an insert as defined above, this method being characterized in that:
--a mixture of bonding-substance particles with an agglomerating agent is produced;
--the metal parts are produced;
--the metal parts are arranged in their desired relative positions, with a layer of the mixture between them; and
--the assembly is raised to a temperature suitable for carrying out both the firing of the mixture and a heat treatment of the metal parts.
In one mode of operation, the said mixture is an aqueous suspension of glass or enamel powder, and the heat treatment is a final quench heat treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative embodiments of the invention will now be described with reference to the appended drawings, in which:
FIG. 1 illustrates, in longitudinal section, the locking of a joint between two metal pipes by means of inserts which are in accordance with the invention;
FIG. 2 represents, in elevation, a variant of the insert of FIG. 1;
FIG. 3 is a partial view, taken in cross-section along the line III--III of FIG. 2;
FIG. 4 is a view similar to FIG. 2, but relative to a second insert variant;
FIG. 5 is a partial view, taken in cross-section along the line V--V of FIG. 4;
FIG. 6 is a view similar to FIG. 2, but relative to a third insert variant;
FIG. 7 is a view from above of one of the two metal parts of the insert of FIG. 6;
FIGS. 8 and 9 correspond respectively to FIGS. 6 and 7, but for a fourth insert variant; and
FIGS. 10 and 11 correspond respectively to FIGS. 6 and 7, but for a fifth insert variant.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows diagrammatically a joint locked between two identical metal pipes, for example spheroidal-graphite cast-iron pipes, including, at one extremity, a smooth male end 1 and, at the opposite extremity, a fitting part 2 of a female end. The joint is sealed automatically, when the smooth end is pushed right into the fitting part, by radial compression of an annular seal 3 (shown only by the contour of its meridional half-section), and the joint is locked by a ring of inserts 4 which are embedded in this seal. The elements 1 to 3 have the same general axis of revolution, assumed to be horizontal. The smooth end has a cylindrical outer surface, chamfered on the outside, at 5, at its extremity.
Except for the composite structure of the inserts 4, which structure will be described in detail later, the joint may, for the requirements of the present description, be considered as identical to that described in the aforementioned published Patent Application FR-2,679,622. It will therefore be necessary to recall only briefly the other elements of the joint.
The fitting part 2 includes an entry flange 6 and then, in succession, from the rear to the front, that is to say going from this flange to the end wall of the fitting part: a relatively deep anchoring groove 7, a shallower sealing cavity 8A and an even shallower front cavity 8B, freely receiving the extremity of the smooth end 1.
The groove 7 is delimited, in succession, by an approximately radial rear wall 9, an inclined flat 10, an end wall 11 and an approximately radial front wall 12.
The seal 3 is a moulded part made of a flexible or resilient material, for example an elastomer, which comprises, at the front, a solid sealing body 13 and, at the rear, an anchoring heel 14 projecting radially outwards and a lip 15 projecting radially inwards.
Each insert 4 is flat and has a mid-plane passing through the axis of the joint. It has the general shape of an L, with a radially outer head 16 embedded in the heel 14 of the seal and a radially inner tail 17 which converges towards the front until slightly projecting over the radially inner face of the seal, approximately halfway along the latter. The head 16 has a rectangular general shape, as does the tail 17, and the latter is terminated by a series of teeth or projections 18.
In order to assemble the joint, the seal is installed in the fitted part, with its heel in the groove 7, and the smooth end is introduced into the fitting part. This bends back the lip 15 and radially compresses the body of the seal in the cavity 8, and the consequence of the forward inclination of the tail 17 of the inserts is that these inserts do not prevent penetration of the smooth end.
Then, in service, when the pipeline is pressurized, the smooth end is stressed towards the rear, that is to say tends to come apart. The inserts 4 limit this backward movement by being braced between the surfaces 10 and/or 11 of the groove 7, against which surfaces the head 16 bears, and the outer surface of the smooth end, into which surface at least one tooth 18 bites. The joint is thus locked.
Each insert 4 consists of two parts made of quench-hardened steel, namely a radially outer part 4A and a radially inner part 4B, the facing junction surfaces of which are connected by an electrically insulating junction layer 4C.
The layer 4C is designed so as to be subjected to stresses which are minimized and are exerted as far as possible in compression, that is to say so as to prevent shear and/or traction as far as possible, and so as to maintain a reliable electrical insulation between the parts 4A and 4B. Its configuration must, of course, be such that each of the parts 4A and 4B touches but one of the two pipes.
Thus, in the example of FIG. 1, the layer 4C is contained in a plane approximately perpendicular to the thrust axis of the insert and cuts the head 16 of the insert in a cross-section of approximately maximum area of this head.
A first embodiment starts with two parts 4A, 4B which have already undergone an appropriate final heat treatment comprising a heating step and a quenching step.
The junction layer 4C may then have various compositions.
A first embodiment variant consists in producing this layer 4C made of a low-creep insulating organic substance, unfilled or filled with particles of non-creeping insulating materials, such as, for example, inorganic powders, especially ceramics. This layer 4C, applied between the junction surfaces of the parts 4A and 4B, then simultaneously ensures the bonding and electrical insulation of the said parts. This solution has the advantage of being inexpensive and simple to implement; in fact, such a layer 4C may be produced at low temperature and there is thus no risk of the steel, of which the parts 4A and 4B are composed, softening.
A second way of producing a junction layer satisfying, economically, the aforementioned requirements, consists in using as layer 4C an inorganic mat, fibrous bed or fabric, which is dense and non-creeping, for example made of glass fibres or ceramic fibres, this mat, fibrous bed or fabric being impregnated or coated on both its faces with an organic substance such as, for example, a resin. This solution has the advantage of not leading to breakdown of the electrical insulation in the event of the organic resin creeping, the mat, fibrous bed or fabric, then remaining interposed between the junction surfaces of the parts 4A and 4B.
In a third variant, the layer 4C is produced by coating, especially by spraying or evaporation, one of the junction surfaces with a layer of a non-creeping inorganic insulation, such as glass, a ceramic or enamel, and then arranging a bonding layer made of an organic substance, especially an epoxy substance, between this coating and the other junction surface. In this way, the possible heating of the parts 4A and 4B is limited to one of the two junction surfaces and to the adjacent zone of the same part. In addition, the quantity of inorganic insulation deposited is reduced to a minimum, which is economical and guarantees that possible creep, in service, of the organic substance will not lead to a metal/metal contact between the two parts 4A, 4B.
Another method of producing the inserts according to the invention consists, in the same cycle, in generating a homogeneous layer 4C possessing the desired properties, and in quenching the parts 4A and 4B by proceeding as follows.
The two parts 4A and 4B are produced by moulding or machining, and a thick aqueous suspension of glass or enamel powder is made up. Next, the two parts are arranged facing each other, interposing some of the suspension between their junction surfaces. The assembly is then heated to a temperature appropriate both for firing the suspension and for carrying out the quench heat treatment of the steel, without impairing the bonding layer, this temperature typically being of the order of 1000° C.
For all the variants which have just been described, it may be advantageous to shape the junction surfaces of the two parts so that the layer 4C can take up, essentially in compression, forces accidentally moving away from the theoretical thrust or bracing direction. In other words, obstacles are thus created to the sliding of the parts 4A and 4B with respect to each other.
Thus, in the example of FIGS. 2 and 3, the layer 4C has a V-shaped profile (possibly upside down as shown by the dot/dash lines), both laterally (FIG. 2) and end-wise (FIG. 3), that is to say has a pyramidal shape. Likewise, in the example of FIGS. 4 and 5, the layer 4C has a wavy profile, both laterally (FIG. 4) and end-wise (FIG. 5). In the case of FIGS. 6 and 7, the obstacles to sliding are perpendicular to the general plane of the layer 4C and may, for example, as shown, be constituted by a cruciform relief provided on one junction surface and by a conjugate recess made in the other junction surface.
On the other hand, in the example of FIGS. 8 and 9, each junction surface is planar (or, as a variant, pseudo-planar) and comprises a central cylindrical recess 19 and a pin 20 made of insulating material such as, for example, an inorganic material made of glass, ceramic or asbestos cement, is housed with a little clearance in these two recesses. The remainder of the junction surfaces is covered by the junction layer 4C produced according to one of the variants described above. As a variant, the cavities 19 could have another shape, especially hemispherical, in which case the pin 20 would be replaced by a ball.
In the example of FIGS. 10 and 11, each junction surface includes a cruciform recess identical to the recess of the part 4B of FIGS. 6 and 7. In order to prevent relative sliding, bars 21, for example cylindrical bars, or alternatively a cross-piece, are used, these being produced from an insulating material and essentially filling the said recesses. | A locking insert 4 for joining the male and female ends of spheroidal-graphite cast-iron pipes conveying fluids under pressure has a generally planar shape, and includes at least two metal parts 4A, 4B fixed to each other by an electrically insulating junction layer 4C. | 5 |
PRIORITY INFORMATION
[0001] The present application is a continuation of U.S. patent application Ser. No. 12/751,558 filed Mar. 31, 2010, which is a continuation of U.S. patent application Ser. No. 12/123,773 filed on May 20, 2008, which is a continuation of U.S. patent application Ser. No. 10/410,988 filed on Apr. 10, 2003, which claims priority to U.S. Provisional Patent Application Ser. No. 60/371,306 filed Apr. 10, 2002.
BACKGROUND OF THE INVENTION
[0002] The invention relates to polymeric materials that are used to conduct electrical signals, and relates in particular to conductive adhesives that are used with medical monitoring sensors that are placed directly on a patient, such as an electro-cardiogram (EKG) sensor.
[0003] Electrically conductive pressure-sensitive adhesives for use in biomedical applications are disclosed, for example, in U.S. Pat. No. 4,848,353. Since such conductive materials typically depend on the presence of water, however, the material must be maintained in a sealed environment until being used. See also, U.S. Pat. No. 5,143,071, which discloses non-stringy adhesive gels for that are hydrophilic.
[0004] Such substances must be isolated from the environment prior to use (e.g., in sealed packages), and may function improperly if allowed to lose water from the conductive material. These limitations adversely affect both the cost of sensors that use such conductive adhesives as well as the amount of use that any particular sensor may enjoy.
[0005] There is a need therefore, for a material that may be used to conduct electricity yet is not susceptible to variations in the water vapor content of the environment in which it is used.
SUMMARY OF THE INVENTION
[0006] In accordance with an embodiment, the invention provides a method of detecting a bioelectrical signal from a subject. The method includes the steps of applying a composite material to a subject wherein the composite material includes a polymeric material and a polar material that is substantially dispersed within the polymeric material; coupling monitoring equipment to the second side of the composite material; permitting the polar material within the polymeric material to respond to the bioelectrical signal within the subject; and detecting a responsive electrical signal from the composite material that is representative of the bioelectrical signal. The polar material exhibits molecular compatibility with the polymeric material such that the polar material neither blooms to a surface of the polymeric material nor crystallizes within the polymeric material, and the composite material has a first side for contacting the subject and a second side.
[0007] In accordance with a further embodiment, the invention provides a method of detecting an alternating current bioelectrical signal from a subject, wherein the method includes the steps of applying a non-ionically conductive composite to a subject wherein the non-ionically conductive composite includes a polymeric material and a polar material that is substantially dispersed within the polymeric material, the composite material having a first side for contacting the subject and a second side; coupling monitoring equipment to the second side of the non-ionically conductive composite material; permitting the polar material within the polymeric material to respond to the alternating current bioelectrical signal as the alternating current bioelectric increases within the subject by aligning with the alternating current bioelectrical signal; permitting the polar material within the polymeric material to respond to the alternating current bioelectrical signal as the alternating current bioelectric current signal decreases within the subject by becoming non-aligned with the alternating current bioelectrical signal, thereby providing a discharge electric field as the polar material becomes non-aligned; and detecting the discharge electric field using the monitoring equipment. The discharge electric field is representative of the alternating current bioelectric signal within the subject.
BRIEF DESCRIPTION OF THE DRAWING
[0008] The following description may be further understood with reference to the accompanying drawings in which:
[0009] FIG. 1 shows an illustrative diagrammatic view of a composite in accordance with an embodiment of the invention;
[0010] FIG. 2 shows an illustrative diagrammatic top view of a monitoring sensor using a composite in accordance with an embodiment of the invention;
[0011] FIG. 3 shows an illustrative diagrammatic side view of the monitoring sensor shown in FIG. 2 taken along line 3 - 3 thereof;
[0012] FIG. 4A shows an illustrative diagrammatic graphical representation of a patent signal being monitored by a conventional hydro-gel sensor;
[0013] FIG. 4B show illustrative diagrammatic graphical representation of a patent signal being monitored by a sensor in accordance with an embodiment of the invention;
[0014] FIG. 4C shows an illustrative diagrammatic graphical representation of a patent signal being monitored by a sensor including a polymeric material but no polar material; and
[0015] FIG. 5 shows an illustrative diagrammatic top view of a conductor pad using a composite in accordance with an embodiment of the invention; and
[0016] FIG. 6 shows an illustrative diagrammatic side view of the conductor pad shown in FIG. 5 taken along line 6 - 6 thereof.
[0017] The drawings are shown for illustrative purposes and are not to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0018] It has been discovered that a polar material (such as an organo salt) may be dispersed within a polymeric material of sufficient concentration that the resulting composite may be responsive to the presence of an alternating current yet not be sensitive to water gain or loss from ambient temperature or humidity conditions. For example, as shown in FIG. 1 , a composite 10 may include an organo salt 12 that is dispersed within a polymeric material 14 . If the organo salt 12 has crystallized out of the polymeric material or has bloomed to the surface, then the salt is not compatible with that given polymer, thus the non-homogenous system will not respond to pick up the alternating current signal. If, on the other hand, the salt becomes dissolved within the polymeric material (rendering the polymeric material clear), then the two materials are compatible, and a substantially homogenous mixture exists to form the desired alternating current responsive blend. When the salt is compatible with the polymer blend, it responds to the rise of an alternating current signal by orienting with the field then returning to a ground state with the collapse of the alternating current field. By responding to the presence of an electric field, therefore, the composite acts as a capacitor in coupling the signal (within a patient) to a sensor.
[0019] A suitable combination of polar material and polymeric material may be identified by the following procedure. First, a polar material is combined with the polymeric material in about five different concentrations (typically between about 5% to about 45% by weight). Then the adhesive-salt composite is drawn onto a release liner (of about 1.5 mil), and permitted to dry and cure. The surface of the composite is then inspected after a short period of time. If the salt has crystallized out or bloomed to the surface, then the combination of components is not compatible. If, on the other hand, the composite is clear, it is subject to the next level of compatibility testing. The samples should then be subjected an exposure test in which the samples are exposed to 100° F. with 95% relative humidity for 3 days. The samples are then again inspected to determine whether the polar material has migrated toward either surface. If there has been no migration of the polar material and the composite is clear, then the dielectric constant for the composite is determined and the composite is tested for use as a medical monitoring material. The dielectric constant, for example, may be at least 50 for signals at 200 Hz.
[0020] In accordance with an embodiment of the invention, the polymeric material may include an acrylic pressure sensitive adhesive such as the V-95 acrylic pressure sensitive adhesive sold by FLEXcon Corporation of Spencer, Mass. The polar material may include a quaternary ammonium organo salt such as the CHEMAX AS-3106 sold by Chemax Corporation of Beaumont, Tex. The percentage by weight of the polar material in the composite may for example, range from about 5% to about 65%, and preferably ranges from about 10% to about 35%.
[0021] As shown in FIGS. 2 and 3 , the composite 10 may be used with medical diagnostic sensor pads in which a metallic contact element 16 is surrounded by the composite 10 and coupled to monitoring equipment via a conductor 18 . The element 16 and composite 10 are positioned within an adhesive plolyethylene foam carrier 20 . In use, the sensor pad is placed on a patient's skin and internal alternating current signals (such as a heart rate) are received by the element 16 through the composite 10 and coupled to the monitoring equipment.
[0022] In further embodiments, the composite 10 may be used in a wide variety of other uses, including for example, other diagnostic sensors, as well as applications in fuel cell technology, battery technology, electro luminescence, or any other application in which an electrical current and/or signal is carried through an electrolyte that has at it's source a dependence on water. Composites of the invention are insensitive to the presence or absence of water vapor, and therefore, do not require high levels of maintenance of certain levels of water in packaging and during use. It has been discovered that the shortcomings of having an electrolyte dependent on the presence of water vapor are avoided by using for example organo-salts (quaternary ammonium salts, organo-sulfates, fluoroboarates, and other salt like materials having some organic functionality). The organic functionality facilitates the salt's organic compatibility with the polymeric material. Organic compatability may not be required when a polymer has compatibility with a purely inorganic salt, e.g., Cesium Iodide. An objective is to provide a polar material such as salt that is at least substantially uniformly dispersed throughout the polymeric material. The water insensitive composite may then respond to an ascending/collapsing electric field via a capacitive coupling. In view of the relatively high volume direct current resistance of this type of doped polymer, the sensitivity is towards alternating current (AC) rather than direct current (DC). The composite, therefore, may even be more effective at detecting an AC signal than carrying an electrical current.
[0023] As discussed above with reference to FIGS. 2 and 3 , composites of the invention may be used in place of electrolytic gels such as hydro-gels in cardiac monitoring pads. The monitoring pad with a composite of the invention described above was used to monitor a person's heart rate and the received signal was compared to signals received using a conventional hydro-gel electrolyte and using the polymeric material without doping with a polar material. As shown in FIG. 4B , the received signal using a composite of the invention (as shown at 24 in FIG. 4A ) provided a nearly identical signal as the conventional hydro-gel electrolyte sensor (as shown at 22 in FIG. 4A ). FIG. 4C shows that the received signal 26 using the polymeric material alone provided no discernable signal information.
[0024] Another variation of these monitoring pads is to provide a polymeric material that has sufficient adhesive qualities to be used itself as the adhesive without requiring the adhesive foam carrier 20 . As shown in FIGS. 5 and 6 , a conductor pad for use in medical applications may include a composite 30 of the invention that is sufficiently adhesive that no additional adhesive is required to maintain contact between a patient's skin and the pad. In this example, the pad used as a conductor to provide electrical signals via conductor 28 to a metallic conductor element 32 . The alternating current field is then coupled to the patient via the composite 30 via the capacitive coupling characteristics of the composite. A supporting material 34 may also be used to provide structural integrity.
[0025] Composites of certain embodiments of the invention have also been tested at varying humidity and over extended periods of time and found to exhibit an insignificant amount of change in performance. Such composites have also been found to provide a recovery time after inducing an overloading current of within 5-10 seconds after the overloading condition was ceased. Although both the hydro-gel and composites of the invention act as a parallel capacitor/resistor, the hydro-gel has a DC resistance of about 500 ohms while a doped adhesive of the invention has a DC resistance of about 100K ohms or higher. The hydro-gel has a capacitance in both high (˜10 kHz) and low (˜200 Hz) frequency ranges in the microfarad range. The doped adhesive of an embodiment of the invention has a more pronounced capacitance that varies with frequency effect from about 230 Pico-farads at 10 kHz to about 1 microfarad at 200 Hz. The dielectric constant K must, therefore, be changing with frequency. In fact, at 10 kHz it is discovered that K is about 10, and at 200 Hz, K is about 10,000 or above. When the K is lower the resistance increases, which requires that the pad impedance and matching impedance of the monitoring equipment must be increased.
[0026] In other embodiments, the polymeric material may include various polymeric materials such as acrylic adhesives that may be distinguished by the relative composition of their monomers and by their molecular weights. For example, acrylic adhesives such as the DURO-TAK 80-1074 acrylic adhesive, the DURO-TAK 80-136A acrylic adhesive, or the DURO-TAK 87-2852 acrylic adhesive each of which sold by National Starch and Chemical Co. of Bridgewater, N.J. may be used as the polymeric material. In certain embodiments, the polar material may include organo-sulfonium, organic ester salts, organo-metallic materials, organo-borates, phosphates and phosfites etc. In particular, the polar material may include a quaternium 18 & isopropyl alcohol (such as the ARQUAD 2HT-75 product), dicocodimoium chloride & isopropyl alcohol (such as the ARQUAD 2C-75 product), stearyl octyldimonium methosulfate (such as the ARQUAD HTL8-MS product) each of which is sold by Akzo Nobel Surface Chemistry LLC of Chicago, Ill., or PEG-5 cocomonium chloride (such as the ETHOQUAD C/25 product sold by Brenntag N.V. of Deerlijk, Belgium). Suitable further specific combinations of polymeric materials and salts are provided in the following table using the above product names.
[0000]
Percent Polar
Polar Material
Polymeric Material
Material by Weight
ARQUAD 2HT-75
87-2852
20%
ARQUAD 2HT-75
87-2852
40%
ARQUAD 2C-75
87-2852
20%
ARQUAD 2C-75
87-2852
40%
ARQUAD 2C-75
80-136A
20%
ARQUAD 2C-75
80-136A
40%
ARQUAD HTL8-MS
87-2852
20%
ARQUAD HTL8-MS
87-2852
40%
ARQUAD HTL8-MS
80-136A
20%
ARQUAD HTL8-MS
80-136A
40%
ETHOQUAD C/25
87-2852
20%
ETHOQUAD C/25
87-2852
40%
ETHOQUAD C/25
80-136A
20%
ETHOQUAD C/25
80-136A
40%
[0027] Composites of the invention may be employed in a wide variety of applications involving the coupling of alternating current electrical activity from one location to another, such as other applications involving the monitoring of electrical activity, or the active application of electrical activity, or even the grounding of undesired electrical activity in, for example, conductive housings.
[0028] Those skilled in the art will appreciate that numerous modifications and variations may be made to the above disclosed embodiments without departing from the spirit and scope of the invention. | A method is disclosed of detecting a bioelectrical signal from a subject. The method includes the steps of applying a composite material to a subject wherein the composite material includes a polymeric material and a polar material that is substantially dispersed within the polymeric material; coupling monitoring equipment to the second side of the composite material; permitting the polar material within the polymeric material to respond to the bioelectrical signal within the subject; and detecting a responsive electrical signal from the composite material that is representative of the bioelectrical signal. The polar material exhibits molecular compatibility with the polymeric material such that the polar material neither blooms to a surface of the polymeric material nor crystallizes within the polymeric material, and the composite material has a first side for contacting the subject and a second side. | 2 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a P2P (peer-to-peer) network system having a function of maintaining the security of a shared file, and more particularly to a technology for maintaining the security of a shared file (share target file) held in peers (peer nodes or peer computers) constituting a P2P network for information distributed sharing under a collaboration P2P application environment that supports collaboration between multiple users on the P2P network and realizes efficient collaboration.
[0002] Generally, communication through the Internet is carried out between clients and servers. In the case of browsing of Web (World Wide Web (WWW)) pages, for instance, personal computers that are attempting to browse the Web pages are the clients and computers holding the Web pages to be displayed are the servers (Web servers). The servers wait for access from the clients at all times and communication is started by connection from the clients to the servers.
[0003] In recent years, however, along with the widespread proliferation of Always On broadband lines, the improvements of the performances of personal computer, and the increases of the disk capacities (storage capacities) of the personal computers, there occur server bottleneck problems in the client/server model (client/server type communication network). Consequently, attention is focused on a P2P model (peer-to-peer type communication network or P2P network) that is an architecture where no server is required. Also, many P2P applications that support collaboration on the P2P network are published and information sharing (such as file sharing) utilizing the P2P applications is increasingly performed.
[0004] Here, as conventional techniques, (1) the P2P and (2) the security of a shared file in the client/server model will be described.
[0005] (1) P2P
[0006] The term “P2P” stands for “peer-to-peer” and the term “peer” has a meaning of “on equal terms”. In the P2P, every computer is on an equal footing and changes its position to a server in some cases and to a client in other cases. The P2P is a framework for contents sharing utilizing resources of peers (peer nodes or peer computers) dynamically connected to the Internet and realizes distributed sharing instead of centralized sharing. Major features of the P2P resides in that it is possible to perform access without paying attention to the locations of contents and that it is possible to take part in contents sharing with ease.
[0007] The Advanced Research Projects Agency Network (ARPANET) that is said as the origin of the Internet was a distributed type network and adopted a mode where it was possible for every computer to perform mutual communication on equal terms. As a result of the widespread proliferation of the Internet, which was started by the public use of the WWW, however, the mutual connection form has been lost because it becomes sufficient that each computer operates as a client and it becomes unnecessary for the computer to function as a server.
[0008] Nowadays, the performances of computers are dramatically improved and the bandwidths of networks are also improved with the advent of the Asymmetric Digital Subscriber Lines (ADSLs) and the like. However, it is not a rare case where access is concentrated on popular sites and therefore servers fall into an overload state or networks are congested. As a technique of solving those problems, the P2P receives attention again.
[0009] As to the P2P, there are two major modes, one of which is the Hybrid P2P and the other of which is the Pure P2P. The Hybrid P2P is a mode where respective nodes (computers) on a network perform the exchange of data through mediation between the nodes and the like by a central server. This mode depends on the central server, so that there is a disadvantage in that the network is stopped at the time of server down but there is an advantage in that information management becomes easy. As a representative application, there is Napster for the exchange of music files.
[0010] In contrast to the Hybrid P2P, the Pure P2P is a mode where no central server is provided. Node information is held in each node itself and the exchange of data is performed only between respective nodes. This mode does not depend on any central server, so that there is a disadvantage in that the management of the node information and the like becomes complicated but there is an advantage in that even if a network is stopped partially, the network will never be stopped entirely. As a representative application, there is Gnutella that is used for the exchange of general-purpose files.
[0011] (2) Security of Shared File in Client/Server Model
[0012] As a technology for performing collaboration in the conventional client/server model, there is a method with which a shared file is held in a file server. In order to maintain the security of the file held in the file server, for instance, a user attempting to access the file server is authenticated, thereby preventing access from an unauthorized user. Also, the file itself held in the file server is encrypted, thereby preventing the contents of the file from being read even if the file is stolen.
[0013] As an example of the user authentication, there is the Source NFS in the Network File System (NFS). This NFS is a network service that allows computers to mutually share their file systems over a Transmission Control Protocol/Internet Protocol (TCP/IP) network.
[0014] The NFS has such a feature that it is possible to access the same file from multiple computers, which makes it possible to save a disk space. In addition, it is possible to collectively manage data, which facilitates management. Consequently, the NFS is widely used as a shared data area of a distributed system and many file servers utilizing the FNS are operated.
[0015] In the NFS, each user issued a request for a service is authenticated on a network by using the Source Remote Procedure Call (RPC) that is an authentication technology for the authentication of a host requesting the service and its user. This process is referred to as the Source NFS.
[0016] As to the encryption of files, there exist several encryption/decryption applications. In many cases, however, the files are encrypted by using information inherent in the files, random numbers, or passwords as key information and the encrypted files are decrypted by using the key information.
[0017] Aside from this, there is also a technique with which the key information used at the time of the encryption of files is subjected to certain processing and is embedded in the headers of the encrypted files. For instance, as a security technology for file sharing among multiple users, Japanese Patent Laid-Open Publication No. 2000-99385 (Patent document 1) proposes a technique with which multiple pieces of encryption key information are embedded in the header of each file, thereby making it possible to decrypt the file with the multiple pieces of key information.
[0018] In the client/server model, the file server rejects the access by each unauthorized user by using the user authentication technology, although the shared files are collectively managed in a stationary manner, so that once unauthorized access is performed, this results in a situation where a large number of files are leaked.
[0019] Also, even when files are held under an encrypted state, if key information used for the encryption is identified, it becomes possible to decrypt the files. In particular, when key information is embedded in the files or the decryption of the files is possible with multiple pieces of key information like in the case of Japanese Patent Laid-Open Publication No. 2000-99385, the probability that the encrypted files will be decrypted is increased.
[0020] On the other hand, in the case of file sharing under a collaboration P2P application environment operating in a P2P network, files to be shared (share target files) are distributed across respective peers, so that it becomes possible to avoid a situation where a large number of files are leaked at a time. Even in this case, however, there still remains a possibility that like in the case of a file server, files will be leaked through unauthorized access. Also, even if the leaked files are encrypted, there is a possibility that the files will be decrypted.
[0021] That is, as to such shared files held in peers under a collaboration P2P application environment operating in a P2P network, a technique for preventing peers holding files from being identified is required in order to prevent unauthorized access. In addition, a technique is also required with which even if files are leaked, it is possible to prevent the contents (information, data) of the files from being read.
[0022] The following are prior arts to the present invention.
[0000] [Patent Document 1]
[0000]
Japanese Patent Laid-Open Publication No. 2000-99385
[Patent Document 2]
Japanese Patent Laid-Open Publication No. 2003-167772
SUMMARY OF THE INVENTION
[0025] An object of the present invention is therefore to provide a technique with which as to divided files of a share target file that are held in multiple peer nodes constituting a P2P network, it is possible to prevent the peer nodes holding the divided files from being identified, thereby preventing unauthorized access.
[0026] Another object of the present invention is to provide a technique with which even when a share target file is leaked, it is possible to prevent the contents of the file from being read.
[0027] To solve the problems described above, according to the present invention, a peer node for constructing a peer-to-peer (P2P) network allowing P2P type communication, includes a unit dividing a share target file for information sharing through the P2P network into a plurality of divided files in a form where contents of each divided file makes no sense by itself; a unit distributing and arranging the plurality of divided files to and in a plurality of peer nodes including an own peer node and at least one other peer node constituting the P2P network; and a unit moving each of the divided files of distribution and arrangement between the plurality of peer nodes at a certain period of time.
[0028] In this case, the dividing unit divides the share target file into at least one first divided file containing only even bits of file constituent data and at least one second divided file containing only odd bits of the file constituent data.
[0029] A peer node according to the present invention, further includes: an interface unit enabling registration of and a search for the share target file from a user terminal; a first management unit managing division information concerning the share target file inputted through the interface unit and divided by the dividing unit using a first storage unit; a first search unit performing, with respect to the share target file requested from the user terminal through the interface unit, a search of the first storage unit in the own peer node and creating a search message to be transmitted to the at least one other peer node; a first control unit exchanging the plurality of divided files of the share target file registered by the first management unit and the search message created by the first search unit with the at least one other peer node; a second search unit searching for transmission destination peer node information requested from the first control unit by using a second storage unit storing adjacent peer node information; a second management unit managing each divided file received by the first control unit using a third storage unit storing reception file information, judging whether each file transfer request from another peer node should be approved or rejected, and requesting the first control unit to transfer the received divided file when a current time has reached a transfer time set for the received divided file; and a restoration unit restoring the share target file based on the plurality of divided files collected by the first search unit.
[0030] A peer node according to the present invention, further includes: a third search unit searching, when the plurality of peer nodes are divided into a plurality of groups, for a transfer destination for each divided file by selecting one peer node from the same group, wherein the divided files are distributed to and arranged in the plurality of peer nodes, including the own peer node and at least one other peer node constituting the P2P network, every the plurality of groups and are moved to another peer node in the same group at a certain period of time.
[0031] In this case, the third search unit searches for transmission destination peer node information requested from the first control unit by using a fourth storage unit storing peer group information.
[0032] According to the present invention, under a collaboration P2P application environment operating in a P2P network, a share target file is divided into multiple divided files and the divided files are moved (transferred or circulated) on the P2P network, thereby preventing peers holding the files from being identified. As a result, it becomes possible to prevent the leakage of the files by unauthorized access.
[0033] Also, according to the present invention, a share target file is divided into multiple divided files and the divided files are held in multiple peer nodes, so that even when data leakage occurs due to unauthorized access or the loss and theft of any of mobile terminals (laptop personal computers, for instance) that constitute the peer nodes, it is impossible to restore the file. As a result, it becomes possible to maintain security.
[0034] Further, according to the present invention, load distribution is achieved through file sharing in the P2P model, so that it becomes possible to prevent a problematic situation occurring in the case of file sharing based on the client/server model, that is, a situation where a server falls into an overload state or traffic in a network is concentrated in a certain part of the network.
[0035] Other objects, features, and advantages of the present invention will become apparent from the following description to be made with reference to the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a block diagram showing constructions of a system and peers of an embodiment of the present invention;
[0037] FIG. 2 is an explanatory diagram of a share target file registration sequence;
[0038] FIG. 3 is an explanatory diagram of a share target file transfer sequence;
[0039] FIG. 4 is an explanatory diagram of a shared file search sequence;
[0040] FIG. 5 is a drawing for explaining a first specific example;
[0041] FIG. 6 is a drawing for explaining the first specific example;
[0042] FIG. 7 is a drawing for explaining the first specific example;
[0043] FIG. 8 is a drawing for explaining the first specific example;
[0044] FIG. 9 is a drawing for explaining the first specific example;
[0045] FIG. 10 is a drawing for explaining a second specific example;
[0046] FIG. 11 is a drawing for explaining the second specific example;
[0047] FIG. 12 is a drawing for explaining the second specific example;
[0048] FIG. 13 is a drawing for explaining the second specific example;
[0049] FIG. 14 is a drawing for explaining a third specific example;
[0050] FIG. 15 is a drawing for explaining the third specific example;
[0051] FIG. 16 is a drawing for explaining the third specific example;
[0052] FIG. 17 is a drawing for explaining the third specific example;
[0053] FIG. 18 is a drawing for explaining a fourth specific example;
[0054] FIG. 19 is a drawing for explaining the fourth specific example;
[0055] FIG. 20 is a drawing for explaining the fourth specific example;
[0056] FIG. 21 is a drawing for explaining the fourth specific example; and
[0057] FIG. 22 is a drawing for explaining the fourth specific example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] The present invention will now be described in more detail with reference to the accompanying drawings. The drawings illustrate a preferred embodiment of the present invention. However, it is possible to carry out the present invention in many different modes and it should not be construed that the present invention is limited to the embodiment described in this specification. If anything, the embodiment is provided in order to thoroughly and completely disclose the present invention and to sufficiently inform persons skilled in the art of the scope of the present invention.
[0059] [Construction of System and Peer]
[0060] Referring to FIG. 1 showing constructions of a system and peers in an embodiment of the present invention, a P2P network system SYS has a function with which under an environment where a file is shared among multiple peers (peer nodes or peer computers) PN by utilizing a P2P network NW, a file to be shared (share target file) is divided into multiple files in units (contents unreadable units) in which it is impossible to read the contents (information, data) of the files, the respective files obtained through the division are distributed to the peers PN in the P2P network NW, and each distributed divided file is moved from one peer PN to another periodically (each time a predetermined certain period of time or a predetermined certain term has passed).
[0061] In this P2P network system SYS, the peers PN constituting the P2P network NW adopt the same construction, accommodate user terminals TE (not sown) through lines NWL of the P2P network NW, and are capable of establishing interconnection. In FIG. 1 , a state is shown in which a peer PN denoted as the “own peer” is connected to other peers PN denoted as the “adjacent peers” through the lines NWL of the P2P network NW.
[0062] In each peer PN, user interface means (unit) 1 provides a user interface through which a user performs registration of a file to be shared and a search for the shared file from his/her user terminal TE. Shared file management means 2 manages information concerning the shared file registered by the user from the user terminal TE through the user interface means 1 by using a shared file information database (shared file DB) 10 .
[0063] Also, in each peer PN, file division means 3 divides the file to be shared registered through the shared file management means 2 into multiple files in the contents unreadable units. Shared file search means 4 searches the shared file DB 10 in the own peer for the divided files of the shared file and creates a search message to the other peers (adjacent peers) in response to a request made by the user using the user terminal TE through the user interface means 1 . Transmission and reception control means 5 exchanges the divided files of the share target file registered by the shared file management means 2 and the search message created by the shared file search means 4 with the other peers.
[0064] Further, in each peer PN, transfer peer search means 6 has a function of searching for transmission destination peer information requested from the transmission and reception control means 5 by using an adjacent peer information database (adjacent peer DB) 11 and a peer group information database (peer group DB) 12 . Reception file information management means 7 manages each divided file received by the transmission and reception control means 5 by using a reception file information database (reception file information DB) 13 and judges whether a file transfer request from another peer should be approved or rejected. In addition, when the current time has reached a transfer time set for a received divided file, the reception file information management means 7 requests the transmission and reception control means 5 to transfer the received divided file to another peer. File restoration means 8 restores the shared file based on the divided files collected by the shared file search means 4 .
[0065] [Basic Operation of System and Peer]
[0066] Next, an example of a basic operation in the P2P network system SYS according to one embodiment of the present invention shown in FIG. 1 will be described. FIG. 2 shows a sequence where a file to be shared is registered, FIG. 3 shows a sequence where divided files of the share target file are transferred, and FIG. 4 shows a sequence where the shared file is searched for.
[0067] First, the share target file registration sequence in the P2P network system SYS according to one embodiment of the present invention will be described with reference to FIGS. 1 and 2 .
[0068] When the user interface means 1 issues a share target file registration request to the shared file management means 2 in response to a request from the user by using the user terminal TE, the shared file management means 2 issues a share target file division request to the file division means 3 in order to divide a share target file to be registered. In response to this share target file division request, the file division means 3 performs file division processing and returns the processing of divided files to the shared file management means 2 . At this time, the pre-division file may be encrypted in order to further enhance security. Then, the shared file management means 2 stores shared file division information, which shows how the file has been divided in the file division means 3 , in the shared file DB 10 .
[0069] Next, the shared file management means 2 issues a fragmented file transfer request to the transmission and reception control means 5 in order to transfer the fragmented files obtained through the division to the multiple other peers PN. In response to this request, the transmission and reception control means 5 issues a transfer destination peer determination request to the transfer peer search means 6 in order to search for other peers PN to which it is possible to transfer the fragmented files. On receiving this request, the transfer peer search means 6 searches for transfer destination peers with reference to the adjacent peer DB 11 or the peer group DB 12 and returns a result of this search to the transmission and reception control means 5 as the transfer destination peers. After the transfer destination peers are determined, the transmission and reception control means 5 performs file transfer processing.
[0070] Next, the sequence where the divided files of the share target file are transferred in the P2P network system SYS will be described with reference to FIGS. 1 and 3 .
[0071] As shown in the sequence in FIG. 3 , after the search for the transfer destination peers, the transmission and reception control means 5 issues a divided file transmission permission request to the transfer destination peers through the lines NWL of the P2P network NW. In each divided file reception peer that has received the divided file transmission permission request, the transmission and reception control means 5 issues a divided file reception permission judgment request to the reception file information management means 7 and passes the processing to the reception file information management means 7 , which then judges whether it is possible to receive the divided file.
[0072] In more detail, the reception file information management means 7 searches the reception file information DB 13 for each file on a divided file list and returns a divided file reception approve/reject judgment result to the transmission and reception control means 5 of the divided file transmission peer. Here, if the divided file has already been received, the divided file reception approve/reject judgment result is set so as to show that the reception is rejected; if not, the divided file reception approve/reject judgment result is set so as to show that the reception is approved.
[0073] The transmission and reception control means 5 of the divided file transmission peer judges whether the transmission is possible with reference to the divided file reception approve/reject judgment result. Then, if the reception is rejected, the transmission and reception control means 5 performs the transfer destination peer search again. On the other hand, if the reception is approved, the transmission and reception control means 5 transmits the divided file to the divided file reception peer, in which the transmitted divided file is registered in the reception file information management means 7 through the transmission and reception control means 5 . The registration processing performed in the reception file information management means 7 includes the accumulation of the file in the reception file information DB 13 and the activation of a timer for divided file transfer in order to hold the file only for a certain period of time.
[0074] Next, the sequence where the divided files of the shared file are searched for in the P2P network system SYS will be described with reference to FIGS. 1 and 4 .
[0075] The user interface means 1 issues a shared file search request to the shared file search means 4 . In response to this request, the shared file search means 4 issues a shared file information search request to the shared file management means 2 in order to extract corresponding shared file information. On receiving this request, the shared file management means 2 searches the shared file DB 10 for the corresponding file information and returns a result of this search to the shared file search means 4 .
[0076] When the shared file information does not exist in the own peer, the shared file search means 4 next searches other peers PN for the shared file information. To do so, the shared file search means 4 searches for the other peers PN through the transmission and reception control means 5 , issues a search message transmission request to the peers PN obtained as a result of the search, and extracts the shared file information. As a result of those operations, even when the shared file information does not exist in the own peer, it is possible to obtain the shared file information. Then, the processing proceeds to the next operation.
[0077] The shared file search means 4 extracts a divided file list from the shared file information and issues a divided file search request to the reception file information management means 7 . In response to this request, the reception file information management means 7 searches the reception file information DB 13 for the divided files and returns a result of this search to the shared file search means 4 . Then, divided file collection from another peer PN is repeated until every divided file is obtained. Following this, the shared file search means 4 issues a divided file restoration request to the file restoration means 8 and the file restoration means 8 restores the original file.
FIRST SPECIFIC EXAMPLE
[0078] Next, a first specific example in the P2P network system SYS according to one embodiment of the present invention shown in FIG. 1 will be described.
[0079] As the first specific example, a file division and sharing technique will be described with which under a condition where the multiple peers PN are not grouped, a share target file (file to be shared) is divided/transferred and shared in the P2P network NW allowing peer-to-peer type communication between the multiple peers PN.
[0080] This file division and sharing technique will be described with reference to a construction of the P2P network NW shown in FIG. 5 , a construction of the shared file DB 10 shown in FIG. 6 , a construction of the adjacent peer DB 11 shown in FIG. 7 , and a construction of the reception file information DB 13 shown in FIGS. 8 and 9 as well as FIGS. 1 to 4 .
[0081] In this example, it is assumed that the peer A divides a share target file, thereby starting processing for sharing the file. Also, it is assumed that each peer A to F is not allowed to possess (save) two or more files (divided files or fragmented files) obtained through the division of the share target file at the same time. Further, it is assumed that for a predetermined certain period of time after the reception of a divided file of the share target file, it is impossible to receive the same divided file or another divided file.
[0082] (1) Division of File (in Peer A)
[0083] When a user using a user terminal TE accommodated in the peer A wishes to share a file FL 1 (file 1 ) while maintaining the security of this file 1 , he/she instructs the shared file management means 2 to share the file 1 from the user terminal TE through the user interface means 1 . Then, the shared file management means 2 requests the file division means 3 to divide the file 1 .
[0084] Fundamentally, the file division means 3 divides the share target file in a form where data (information) contained in each divided file makes no sense by itself. In this example, the file division means 3 divides the file 1 into a first file F 1 a (file 1 a ) corresponding to a result of extraction of only even bits of the file (more strictly, file constituent data) and a second file F 1 b (file 1 b ) corresponding to a result of extraction of only odd bits of the file.
[0085] Then, the file division means 3 adds a header to each of those divided files 1 a and 1 b . The information contained in this header is a file transfer time interval, a divided file reception reject time interval, a divided file list, and a transfer peer list. The file transfer time interval is a period of time between the reception of the divided file by a certain peer and the transfer to the next peer. The divided file reception reject time interval is a period of time during which it is impossible to receive any of the divided files generated through the division of the shared file after the last divided file transfer. As to the shared file 1 in this example, the file transfer time interval is set at “10 minutes” and the divided file reception reject time interval is set at “20 minutes”.
[0086] Also, the divided file list is a list of the divided files that are necessary to restore the shared file. In more detail, the file 1 a and the file 1 b are on this divided file list. The transfer peer list is a list of peers through which the divided file has passed as a result of transfer based on the file transfer time interval. In this example, previous three reception peers are saved on the transfer peer list, with the oldest reception peer being at the start of the list.
[0087] (2) Registration of File Division Information (in Peer A)
[0088] After the division of the share target file 1 , the file division means 3 of the peer A passes the pre-division file (file 1 ) and the post-division files (files 1 a and 1 b ) to the shared file management means 2 . Then, the shared file management means 2 registers information concerning the divided files 1 a and 1 b of the file 1 in the shared file DB 10 (see FIG. 6 ).
[0089] The shared file DB 10 is a database giving the division information concerning each file provided by the own peer and shared in the P2P network NW. In the shared file DB 10 , each division number is the number of divided files of a shared file and each divided file list is a list of the names of post-division files of a shared file. The divided file list is referred to at the time of restoration of the shared file.
[0090] When the registration of the file division information into the shared file DB 10 is completed, the shared file management means 2 deletes the pre-division file (file 1 ), passes the post-division files (files 1 a and 1 b ) and the file division information to the transmission and reception control means 5 , and requests the transfer of the divided files.
[0091] (3) Search for Transfer Destination Peer (in Peer A)
[0092] On receiving the divided file transfer request from the shared file management means 2 , the transmission and reception control means 5 requests the transfer peer search means 6 to search for divided file transfer destination peers. In response to this request, the transfer peer search means 6 searches for the divided file transfer destination peers. In more detail, the transfer peer search means 6 randomly extracts peers, whose number is equal to the number of the divided files, from the adjacent peer DB 11 (see FIG. 7 ). The contents of the adjacent peer DB 11 are a list of Internet Protocol (IP) addresses of the adjacent peers B, C, and F that are each a peer whose existence is known by the peer A in advance and with which it is possible for the peer A to perform direct communication. In this example, at the time when the peer A takes part in the P2P network NW, the contents of the adjacent peer DB 11 are registered.
[0093] Then, the transfer peer search means 6 returns the peer names and IP addresses of the transfer destination peers, whose number is equal to the number of the divided files, to the transmission and reception control means 5 . Following this, the transmission and reception control means 5 determines a transfer destination peer for each divided file with reference to the transfer destination peer information received from the transfer peer search means 6 and issues a file transfer request to the transfer destination peer. In this example, the transmission and reception control means 5 of the peer A transfers the divided file 1 a to the adjacent peer B and transfers the divided file 1 b to the adjacent peer C. Note that in the following description, only the transfer of the file 1 a to the peer B will be explained.
[0094] (4) Transfer of File (Negotiation with Transfer Destination Peer B)
[0095] In order to request the transfer destination peer B to receive the divided file 1 a , the transmission and reception control means 5 of the peer A transmits the header of the divided file 1 a through the line NWL of the P2P network NW. After receiving the header of the divided file 1 a , the transmission and reception control means 5 of the peer B passes the divided file list in the divided file header to the reception file information management means 7 , which then confirms whether any of the divided files of the shared file 1 has already been received.
[0096] In more detail, the reception file information management means 7 refers to the reception file information DB 13 (see FIG. 8 ) and searches for each file name contained in the divided file list. The reception file information DB 13 is a database composed of multiple columns named “divided file name”, “file reception time”, “file transfer time interval (transfer interval)”, “file transfer time”, “file reception reject time interval”, “file reception reject time”, and “transfer peer list”. The reception file information DB 13 having this construction is used to manage the time of a received divided file transfer to the next peer and to determine whether the reception of a divided file of a certain shared target file is approved or rejected.
[0097] When the divided file names contained in the divided file list do not exist in the reception file information DB 13 , this corresponds to a situation where none of the divided files of the share target file 1 is under reception or under reception rejection. Consequently, if the divided file names do not exist, the reception file information management means 7 of the peer B returns information showing that the file reception is approved to the transmission and reception control means 5 . On the other hand, when any of the divided file names exists, this corresponds to a situation where any of the divided files of the share target file 1 is under reception or under reception rejection, so that the reception file information management means 7 returns information showing that the reception is rejected to the transmission and reception control means 5 .
[0098] When receiving the information showing that the file reception is approved from the reception file information management means 7 , the transmission and reception control means 5 returns a reception permission notification to the peer A. On receiving this reception permission notification from the transfer destination peer B through the line NWL, the transmission and reception control means 5 of the peer A transfers the divided file 1 a to the peer B through the line NWL.
[0099] (5) Reception of File (Processing in Peer B)
[0100] After receiving the divided file 1 a transmitted from the transmission and reception control means 5 of the peer A, the transmission and reception control means 5 of the peer B stores the received divided file 1 a in a disk apparatus and then passes the file name, header information (file transfer time interval, divided file reception reject time interval, transfer peer list), and file reception time of the received file to the reception file information management means 7 .
[0101] The reception file information management means 7 registers the received file name, file reception time, and header information (file transfer time interval, divided file reception reject time interval, and transfer peer list) of the received file as well as a transfer time and a reception reject time calculated from those information in the reception file information DB 13 . An example of the reception file information DB 13 after this registration processing is shown in FIG. 9 .
[0102] Then, the reception file information management means 7 activates a timer for transfer of the file 1 a based on the file transfer time interval in the received file header. When this timer has timed out, the reception file information management means 7 passes the name and the transfer peer list of the divided file obtained from the reception file information DB 13 to the transmission and reception control means 5 and requests the transfer of the file 1 a to another peer.
[0103] (6) Transfer of File (Processing in Peer B)
[0104] On receiving the transfer request issued as a result of the time-out of the timer for the transfer of the divided file 1 a , the transmission and reception control means 5 of the peer B passes the transfer peer list to the transfer peer search means 6 and requests a search for the next transfer peer.
[0105] On receiving this request, the transfer peer search means 6 determines a transfer destination peer through the same processing as in (3) described above. Note that each peer contained in the transfer peer list is excluded from the candidates for the transfer destination peer. Also, when no peer other than the peers contained in the transfer peer list exists as the candidates for the transfer destination peer, a transfer peer at the start of the transfer peer list, that is, the oldest transfer peer is set as the transfer destination peer.
[0106] In this example, it is assumed that the transfer peer search means 6 has determined the adjacent peer D as the transfer destination peer. Therefore, the transfer peer search means 6 passes the peer name and IP address of the peer D to the transmission and reception control means 5 . Then, the transmission and reception control means 5 performs the same processing as in (4) described above to thereby request the transfer destination peer D to judge whether the file transfer is approved or rejected.
[0107] If the transfer to the peer D is possible, the transmission and reception control means 5 adds the own peer B to the transfer peer list of the file 1 a and then transfers the file 1 a to the peer D. When the number of peers registered on the transfer peer list has already reached a registration limit number (“3” in this example), the transmission and reception control means 5 deletes the oldest peer before adding the peer B. After the transfer to the peer D is completed, the transmission and reception control means 5 deletes the divided file 1 a saved in the disk apparatus.
[0108] In this manner, the divided file 1 a is moved from one peer to another each time a certain period of time has passed. As a result, it becomes possible to secure security.
SECOND SPECIFIC EXAMPLE
[0109] Next, a second specific example in the P2P network system SYS according to one embodiment of the present invention shown in FIG. 1 will be described.
[0110] As the second specific example, a file acquisition technique will be described with which a file divided/transferred and shared with the same file division and sharing technique as in the first specific example described above is searched for and acquired. Like in the first specific example, this second specific example will be described under a condition where the multiple peers PN in the P2P network NW allowing peer-to-peer type communication between the multiple peers PN are not grouped.
[0111] The file acquisition technique will be described with reference to a construction of the P2P network NW shown in FIG. 10 , a construction of the shared file DB 10 shown in FIG. 11 , a construction of the adjacent peer DB 11 shown in FIG. 12 , and a construction of the reception file information DB 13 shown in FIG. 13 as well as FIGS. 1 to 4 .
[0112] In this example, it is assumed that in the construction of the P2P network NW shown in FIG. 10 , the peer B has divided a share target file FL 1 (file 1 ) into three files FL 1 a , FL 1 b , and FL 1 c (files 1 a , 1 b , and 1 c ) for sharing. Also, it is assumed that at 11 o'clock (11:00), the peer A receives a request to search for the shared file 1 from a user and starts processing for acquiring the file 1 . Further, it is assumed that at the point in time when the file search is started (11:00 o'clock) the respective divided files that are the file 1 a , the file 1 b , and the file 1 c exist (is held or possessed) in the peer A, the peer C, and the peer E, respectively.
[0113] (1) Search for Divided File List (in Peer A)
[0114] When a user using a user terminal TE accommodated in the peer A wishes to acquire the shared file 1 , he/she requests the shared file search means 4 to search for the file 1 from the user terminal TE through the user interface means 1 . On receiving the request to search for the file 1 from the user through the user interface means 1 , the shared file search means 4 inquires of the shared file management means 2 about whether the divided file list of the file 1 is possessed.
[0115] On receiving this inquiry, the shared file management means 2 refers to the shared file DB 10 (see FIG. 11 ) and searches for an entry corresponding to the file 1 . In the shared file DB 10 , an entry is created only for each file that was possessed and divided/transferred for sharing in the own peer. In this example, the peer that performed the division and sharing processing on the file 1 is the peer B, so that the entry corresponding to the file 1 does not exist in the shared file DB 10 .
[0116] (2) Search for Divided File List (Between Peers)
[0117] When the shared file information on the file 1 was not detected by the shared file management means 2 of the peer A, the shared file search means 4 then requests the transmission and reception control means 5 to transmit a message to search for the shared file information on the file 1 to other peers.
[0118] On receiving this request, the transmission and reception control means 5 inquires of the transfer peer search means 6 about every piece of adjacent peer information. In response to this inquiry, the transfer peer search means 6 refers to the adjacent peer DB 11 (see FIG. 12 ) and returns the IP addresses of the registered peers B, C, and F to the transmission and reception control means 5 . Then, the transmission and reception control means 5 transmits a shared file search message concerning the file 1 to the adjacent peers B, C, and F.
[0119] In each of the adjacent peers B, C, and F received this search message, the transmission and reception control means 5 inquires of the shared file management means 2 about a possessing state, that is, whether the shared file information on the file 1 is possessed in the own peer through the shared file search means 4 . In this example, the shared file management means 2 of the peer B informs the transmission and reception control means 5 of the own peer B that the shared file information on the file 1 is possessed. Consequently, the transmission and reception control means 5 of the peer B transfers the shared file information on the file 1 to the peer A.
[0120] The transmission and reception control means 5 of the peer A receives the shared file information on the file 1 and passes the shared file information on the file 1 to the shared file search means 4 .
[0121] (3) Search for Divided File (in Peer A)
[0122] The shared file search means 4 of the peer A refers to the divided file list in the shared file information received from the transmission and reception control means 5 and acquires a list of files that are necessary to restore the file 1 . Then, the shared file search means 4 inquires of the reception file information management means 7 about whether any of the divided files 1 a , 1 b , and 1 c on the divided file list is possessed in the own peer.
[0123] On receiving the divided file inquiry from the shared file search means 4 , the reception file information management means 7 refers to the reception file information DB 13 (see FIG. 13 ) and searches for an entry corresponding to any of the divided files 1 a , 1 b , and 1 c . As a result of this search, an entry corresponding to the file 1 a is found in the reception file information DB 13 . Then, the reception file information management means 7 confirms the transfer time in the detected entry corresponding to the file 1 a . In this example, the transfer time “11:10” in the corresponding entry succeeds the current time “11:00”, so that it is found that the file 1 a is not yet transferred, that is, the file 1 a exists in the own peer. Consequently, the reception file information management means 7 acquires the divided file 1 a from the reception file information DB 13 and passes it to the shared file search means 4 .
[0124] (4) Search for Divided File (Between Peers)
[0125] After receiving a result of the search from the reception file information management means 7 in the peer A, the shared file search means 4 requests the transmission and reception control means 5 to transmit a message to search for the divided files 1 b and 1 c to other peers in order to obtain the divided files 1 b and 1 c other than the detected divided file 1 a.
[0126] On receiving the request, the transmission and reception control means 5 inquires of the transfer peer search means 6 about every piece of adjacent peer information. In response to this inquiry, the transfer peer search means 6 returns the IP addresses of the peers B, C, and F registered in the adjacent peer DB 11 (see FIG. 12 ) to the transmission and reception control means 5 . Then, the transmission and reception control means 5 transmits the message to search for the file 1 b and the file 1 c to the adjacent peers B, C, and F through the lines NWL of the P2P network NW.
[0127] In each of the adjacent peers B, C, and F received the search message, the transmission and reception control means 5 inquires of the reception file information management means 7 about a possessing state, that is, whether the file 1 b or 1 c is possessed in the own peer. In the peer C, the reception file information management means 7 informs the transmission and reception control means 5 that the file 1 b exists in the own peer. Then, the transmission and reception control means 5 transfers the file 1 b to the peer A through the line NWL.
[0128] Then, each of the adjacent peers B, C, and F further transmits the search message to its adjacent peers. This search message is repeatedly transferred a predetermined number of times. As a result of this repetitive transfer of the search message, the peer E receives the search message issued by the peer A from its adjacent peer after a while. In the peer E, the reception file information management means 7 informs the transmission and reception control means 5 that the file 1 c exists in the own peer. Then, the transmission and reception control means 5 transfers the file 1 c to the peer A through the line NWL.
[0129] (5) Restoration of Shared File (in Peer A)
[0130] After receiving the file 1 b from the peer C and receiving the file 1 c from the peer E, the transmission and reception control means 5 of the peer A passes those files 1 b and 1 c to the shared file search means 4 . After acquiring all of the divided files 1 a , 1 b , and 1 c that are necessary to restore the file 1 in this manner, the shared file search means 4 passes the divided files 1 a , 1 b , and 1 c to the file restoration means 8 .
[0131] The file restoration means 8 restores the file 1 based on the divided files 1 a , 1 b , and 1 c and returns the restored file 1 to the shared file search means 4 . Then, the shared file search means 4 provides the user terminal TE with the file 1 (requested shared file) through the user interface means 1 and the line NWL.
THIRD SPECIFIC EXAMPLE
[0132] Next, a third specific example in the P2P network system SYS according to one embodiment of the present invention shown in FIG. 1 will be described.
[0133] As the third specific example, a file division and sharing technique will be described with which under a condition where the multiple peers PN are grouped, a share target file (file to be shared) is divided/transferred and shared in the P2P network NW allowing peer-to-peer type communication between the multiple peers PN. In this example, multiple groups of the multiple peers PN are formed (grouping of the peers is performed) in the P2P network NW and each divided file is sequentially transferred in one of the multiple groups. Each peer PN belongs to only one group and is incapable of belonging to multiple groups.
[0134] This file division and sharing technique will be described with reference to a construction of the P2P network NW shown in FIG. 14 , a construction of the shared file DB 10 shown in FIG. 15 , a construction of the peer group DB 12 shown in FIG. 16 , and a construction of the reception file information DB 13 shown in FIG. 17 as well as FIGS. 1 to 4 .
[0135] In this example, it is assumed that the peer A divides a share target file, thereby starting processing for sharing the file. Also, it is assumed that each peer A to F is not allowed to possess (save) two or more files (divided files or fragmented files) obtained through the division of the share target file at the same time. Further, it is assumed that for a predetermined certain period of time after the reception of a divided file of the share target file, it is impossible to receive the same divided file or another divided file. Still further, it is assumed that each group, to which one of the peers A to F belongs, is one of a group #1 and a group #2, with the peers A, B, and D belonging to the group #1 and the peers C, E, and F belonging to the group #2.
[0136] (1) Division of File (in Peer A)
[0137] When a user using a user terminal TE accommodated in the peer A wishes to share a share target file FL 1 (file 1 ) while maintaining the security of this file 1 , he/she instructs the shared file management means 2 to share the file 1 from the user terminal TE through the user interface means 1 . Then, the shared file management means 2 requests the file division means 3 to divide the file 1 .
[0138] Fundamentally, the file division means 3 divides the share target file in a form where data (information) contained in each divided file makes no sense by itself. In this example, the file division means 3 divides the file 1 into a first file F 1 a (file 1 a ) corresponding to a result of extraction of only even bits of the file (more strictly, file constituent data) and a second file F 1 b (file 1 b ) corresponding to a result of extraction of only odd bits of the file.
[0139] Then, the file division means 3 adds a header to each of those divided files 1 a and 1 b . The information contained in this header is a file transfer time interval, a divided file list, and a transfer peer list. The file transfer time interval is a period of time between the reception of the divided file by a certain peer and the transfer to the next peer. As to the shared file 1 in this example, the file transfer time interval is set at “10 minutes”.
[0140] Also, the divided file list is a list of the divided files that are necessary to restore the shared file. In more detail, the file 1 a and the file 1 b are on this divided file list. The transfer peer list is a list of peers through which the divided file has passed as a result of transfer based on the file transfer time interval. In this example, previous two reception peers are saved on the transfer peer list, with the oldest reception peer being at the start of the list.
[0141] (2) Registration of File Division Information (in Peer A)
[0142] After the division of the share target file 1 , the file division means 3 of the peer A passes the pre-division file (file 1 ) and the post-division files (files 1 a and 1 b ) to the shared file management means 2 . Then, the shared file management means 2 registers information concerning the divided files 1 a and 1 b of the file 1 in the shared file DB 10 (see FIG. 15 ).
[0143] The shared file DB 10 is a database giving the division information concerning each file provided by the own peer and shared in the P2P network NW. In the shared file DB 10 , each division number is the number of divided files of a shared file and each divided file list is a list of the names of post-division files of a shared file. The divided file list is referred to at the time of restoration of the shared file.
[0144] When the registration of the file division information into the shared file DB 10 is completed, the shared file management means 2 deletes the pre-division file (file 1 ), passes the post-division files (files 1 a and 1 b ) and the file division information to the transmission and reception control means 5 , and requests the transfer of the divided files.
[0145] (3) Search for Transfer Destination Peer (in Peer A)
[0146] On receiving the request to transfer the divided files from the shared file management means 2 , the transmission and reception control means 5 requests the transfer peer search means 6 to search for divided file transfer destination peers. On receiving this search request, the transfer peer search means 6 searches for the divided file transfer destination peers. In order to transfer the respective divided files to mutually different groups, the transfer peer search means 6 needs to select one peer from each group. In order to select peers whose number is equal to the number of the divided files, the transfer peer search means 6 refers to the peer group DB 12 (see FIG. 16 ) that manages the peers belong to each peer group and randomly selects one peer from each peer group.
[0147] The peer group DB 12 is a database where each peer existing in the P2P network NW, the group to which the peer belongs, and the IP address of the peer are registered. In this example, at the time when each peer takes part in the P2P network NW, the contents of the peer group DB 12 are registered. It does not matter whether this peer group DB 12 is held in each peer or is held in a Hybrid P2P management server. When the peer group DB 12 is held in the management server, the transfer peer search means 6 sends an inquiry to the management server through the transmission and reception control means 5 and the line NWL of the P2P network NW. In this example, the transfer peer search means 6 selects the peer B from the group #1 and selects the peer C from the group #2 and passes the IP addresses of the peers B and C to the transmission and reception control means 5 .
[0148] It should be noted here that a peer group search means that is dedicated to this transfer destination peer search processing may be provided between the transfer peer search means 6 and the peer group DB 12 . In this case, through cooperation between the peer group search means and the transfer peer search means 6 , the processing for searching for the transfer destination peers is carried out.
[0149] (4) Transfer of File (Negotiation with Transfer Destination-Peer B)
[0150] In order to transmit the divided file 1 a to the peer B and to transmit the divided file 1 b to the peer C through the lines NWL of the P2P network NW, the transmission and reception control means 5 of the peer A first transmits the file name and header information of the file 1 a to the peer B and transmits the file name and header information of the file 1 b to the peer C. The processing in the peer B and the processing in the peer C are the same, so that in the following description, only the processing in the peer B will be explained.
[0151] On receiving the file name and the header information from the peer A through the line NWL, the transmission and reception control means 5 of the peer B passes the transfer peer list in the header to the reception file information management means 7 . Then, the reception file information management means 7 refers to the reception file information DB 13 (see FIG. 17 ) and confirms that the file 1 a does not exist. The reception file information DB 13 is a database composed of multiple columns named “divided file name”, “file reception time”, “file transfer time interval (transfer interval)”, “file transfer time”, and “transfer peer list” and is used to manage the transfer time of each received divided file to the next peer and to determine whether the reception of a divided file of a certain shared target file is approved or rejected.
[0152] In addition, the reception file information management means 7 confirms that the own peer (peer B) is not contained in the transfer peer list of the header information. Following this, the reception file information management means 7 informs the transmission and reception control means 5 that the reception is permitted. Then, the transmission and reception control means 5 returns a reception permission notification to the peer A through the line NWL.
[0153] On receiving the reception permission notification from the peer B, the transmission and reception control means 5 of the peer A transmits the file 1 a to the peer B.
[0154] (5) Reception of File (Processing in Peer B)
[0155] After receiving the divided file 1 a transmitted from the transmission and reception control means 5 of the peer A, the transmission and reception control means 5 of the peer B stores the received divided file 1 a in a disk apparatus and then passes the file name, header information (file transfer time interval, transfer peer list) and file reception time of the received file to the reception file information management means 7 .
[0156] The reception file information management means 7 registers the received file name, file reception time, and file transfer time interval and transfer peer list within the received file header of the received file as well as a transfer time calculated from those information in the reception file information DB 13 . An example of the reception file information DB 13 after this registration processing is shown in FIG. 17 .
[0157] Then, the reception file information management means 7 activates a timer for transfer of the file 1 a based on the file transfer time interval in the received file header. When this timer has timed out, the reception file information management means 7 passes the name and the transfer peer list of the divided file obtained from the reception file information DB 13 to the transmission and reception control means 5 and requests the transfer of the file 1 a to another peer.
[0158] (6) Transfer of File (Processing in Peer B)
[0159] On receiving the transfer request issued as a result of the time-out of the timer for the transfer of the divided file 1 a , the transmission and reception control means 5 of the peer B passes the transfer peer list to the transfer peer search means 6 and requests a search for the next transfer peer.
[0160] In order to select a peer belonging to the same group based on the received transfer peer list, the transfer peer search means 6 refers to the peer group DB 12 and selects the peer D that belongs to the group (group #1), which is the same as the group to which the own peer belongs, and is not contained in the transfer peer list. When every peer in the same group is contained in the transfer peer list, the transfer peer search means 6 selects the oldest peer on the transfer peer list.
[0161] Then, the transfer peer search means 6 passes the peer name and the IP address of the selected peer D to the transmission and reception control means 5 . After adding the own peer (peer B) to the transfer peer list of the file 1 a , the transmission and reception control means 5 transmits the file 1 a to the transfer destination peer D through the line NWL. When the number of peers registered on the transfer peer list has already reached a registration limit number (“2” in this example), the transmission and reception control means 5 deletes the oldest peer before adding the peer B. After the transfer to the peer D is completed, the transmission and reception control means 5 deletes the divided file 1 a saved in a disk apparatus.
[0162] In this manner, the divided file 1 a is moved from one peer to another each time a certain period of time has passed. As a result, it becomes possible to secure security.
FOURTH SPECIFIC EXAMPLE
[0163] Next, a fourth specific example in the P2P network system SYS according to one embodiment of the present invention shown in FIG. 1 will be described.
[0164] As the fourth specific example, a file acquisition technique will be described with which a file divided/transferred and shared with the same file division and sharing technique as in the third specific example described above is searched for and acquired. Like in the third specific example, this fourth specific example will be described under a condition where the multiple peers PN in the P2P network NW allowing peer-to-peer type communication between the multiple peers PN are grouped.
[0165] In this example, multiple groups of the multiple peers PN are formed (grouping of the peers is performed) in the P2P network NW. Each peer PN belongs to only one group and is incapable of belonging to multiple groups. Also, it is assumed that each group, to which one of the peers PN belongs, is one of a group #1 and a group #2.
[0166] The file acquisition technique will be described with reference to a construction of the P2P network NW shown in FIG. 18 , a construction of the shared file DB 10 shown in FIG. 19 , a construction of the adjacent peer DB 11 shown in FIG. 20 , and a construction of the reception file information DB 13 shown in FIG. 22 as well as FIGS. 1 to 4 .
[0167] In this example, it is assumed that in the construction of the P2P network NW shown in FIG. 18 , the peer B has divided a share target file FL 1 (file 1 ) into two files FL 1 a and FL 1 b , (files 1 a and 1 b ) for sharing. Also, it is assumed that at 11 o'clock (11:00), the peer A receives a request to search for the shared file 1 from a user and starts processing for acquiring the file 1 . Further, it is assumed that at the point in time when the file search is started (11:00 o'clock), the respective divided files that are the file 1 a and the file 1 b exist (is held or possessed) in the peer A and the peer E, respectively. In addition, the peer A, B, and D belong to Group #1, and the peer C, E, and F belong to Group #2.
[0168] (1) Search for Divided File List (in Peer A)
[0169] When a user using a user terminal TE accommodated in the peer A wishes to acquire the shared file 1 , he/she requests the shared file search means 4 to search for the file 1 from the user terminal TE through the user interface means 1 . On receiving the request to search for the file 1 from the user through the user interface means 1 , the shared file search means 4 inquires of the shared file management means 2 about whether the divided file list (shared file information) of the file 1 is possessed.
[0170] The shared file management means 2 refers to the shared file DB 10 (see FIG. 19 ) and searches for an entry corresponding to the file 1 . In the shared file DB 10 , an entry is created only for each file that was possessed and divided/transferred for sharing in the own peer. In this example, the peer that performed the division and sharing processing on the file 1 is the peer B, so that the entry corresponding to the file 1 does not exist in the shared file DB 10 .
[0171] (2) Search for Divided File List (Between Peers)
[0172] When the shared file information on the file 1 was not detected by the shared file management means 2 of the peer A, the shared file search means 4 then requests the transmission and reception control means 5 to transmit a message to search for the shared file information on the file 1 to other peers.
[0173] On receiving this request, the transmission and reception control means 5 inquires of the transfer peer search means 6 about every piece of adjacent peer information. In response to this inquiry, the transfer peer search means 6 refers to the adjacent peer DB 11 (see FIG. 20 ) and returns the IP addresses of the registered peers B, C, and F to the transmission and reception control means 5 . Then, the transmission and reception control means 5 transmits a shared file search message concerning the file 1 to the adjacent peers B, C, and F.
[0174] In each of the adjacent peers B, C, and F received this search message, the transmission and reception control means 5 inquires of the shared file management means 2 about a possessing state, that is, whether the shared file information on the file 1 is possessed in the own peer through the shared file search means 4 . In this example, the shared file management means 2 of the peer B informs the transmission and reception control means 5 of the own peer B that the shared file information on the file 1 is possessed. Consequently, the transmission and reception control means 5 of the peer B transfers the shared file information on the file 1 to the peer A.
[0175] The transmission and reception control means 5 of the peer A receives the shared file information on the file 1 and passes the shared file information on the file 1 to the shared file search means 4 .
[0176] (3) Search for Divided File (in Peer A)
[0177] The shared file search means 4 of the peer A refers to the divided file list in the shared file information received from the transmission and reception control means 5 and acquires a list of files that are necessary to restore the file 1 . Then, the shared file search means 4 inquires of the reception file information management means 7 about whether any of the divided files 1 a and 1 b on the divided file list is possessed in the own peer.
[0178] On receiving the divided file inquiry from the shared file search means 4 , the reception file information management means 7 refers to the reception file information DB 13 (see FIG. 22 ) and searches for an entry corresponding to any of the divided files 1 a and 1 b . As a result of this search, an entry corresponding to the file 1 a is found in the reception file information DB 13 . Existence of the entry means the existence of the divided file 1 a exists in the own peer.
[0179] In other words, the reception file information management means 7 confirms the transfer time in the detected entry of the file 1 a . The transfer time “11:10” in the corresponding entry succeeds the current time “11:00”, so that it is found that the file 1 a is not yet transferred, that is, the file 1 a exists in the own peer. Consequently, the reception file information management means 7 acquires the divided file 1 a from the reception file information DB 13 and passes it to the shared file search means 4 .
[0180] (4) Search for Divided File (Between Peers)
[0181] After receiving a result of the search from the reception file information management means 7 in the peer A, the shared file search means 4 requests the transmission and reception control means 5 to transmit a message to search for the divided file 1 b to other peers in order to obtain the divided file 1 b other than the detected divided file 1 a.
[0182] On receiving the search message, the transmission and reception control means 5 inquires of the transfer peer search means 6 about every piece of peer group information. Then, the transfer peer search means 6 randomly selects one peer from each group registered in the peer group DB 12 shown in FIG. 21 and returns the selected peer to the transmission and reception control means 5 . In this example, the peer D is selected from the group #1 and the peer F is selected from the group #2. Then, the transmission and reception control means 5 transmits the message to search for the file 1 b to the peers D and F through the lines NWL.
[0183] In each of the peers D and F received the search message from the peer A, the transmission and reception control means 5 inquires of the reception file information management means 7 about a possessing state, that is, whether the file 1 b is possessed in the own peer. In response to this inquiry, the reception file information management means 7 refers to the reception file information DB 13 and searches for an entry corresponding to the file 1 b.
[0184] If the entry exists, the reception file information management means 7 informs the transmission and reception control means 5 that the file 1 b exists in the own peer. Then, the transmission and reception control means 5 transfers the file 1 b to the peer A through the line NWL. On the other hand, if the entry does not exist, the transfer peer search means 6 selects every peer belonging to the same group from the peer group DB 12 and the transmission and reception control means 5 cooperating with the transfer peer search means 6 transfers the search message to every peer in the group.
[0185] On receiving the search message from the peer F, the reception file information management means 7 in the peer E informs the transmission and reception control means 5 that the file 1 b exists in the own peer. Then, the transmission and reception control means 5 transfers the file 1 b to the peer A through the line NWL.
[0186] (5) Restoration of Shared File (in Peer A)
[0187] After acquiring the divided files 1 a and 1 b that are necessary to restore the shared file 1 in this manner, the transmission and reception control means 5 in the peer A passes those divided files 1 a and 1 b to the shared file search means 4 . Then, the shared file search means 4 passes the received divided files 1 a and 1 b to the file restoration means 8 .
[0188] The file restoration means 8 restores the file 1 based on the divided files 1 a and 1 b , and returns the restored file 1 to the shared file search means 4 . As a result, the shared file search means 4 provides the user terminal TE with the file 1 (requested shared file) through the user interface means 1 and the line NWL.
[0189] [Modification]
[0190] In the embodiment described above, the multiple peers constituting the P2P network NW may possess (save) files (divided files or fragmented files) obtained through the division of a certain share target file in a dual manner. In this case, it becomes possible to restore the original file even when mobile terminals (such as laptop personal computers) constitute the peers and any of the mobile terminals is stolen or lost.
[0191] Also, it is possible to carry out the present invention with a program that causes a computer to execute the processing described in the embodiment. In this case, it is possible to provide the program by using a recording medium, such as a CD-ROM or a flexible disk, or through a communication line.
[0192] Further, it is possible to carry out the present invention by selecting arbitrary ones or all of the respective operations described in the embodiment and combining them with each other.
INDUSTRIAL APPLICABILITY
[0193] The present invention is applicable, for instance, to an electronic document file containing confidential information shared for a project in a company or the like. | A peer node according to the present invention relates to a peer node for constructing a peer-to-peer (P2P) network allowing P2P type communication. The peer node includes a unit dividing a share target file for information sharing through the P2P network into a plurality of divided files in a form where contents of each divided file makes no sense by itself; a unit distributing and arranging the plurality of divided files to and in a plurality of peer nodes including the own peer node and at least one other peer node constituting the P2P network; and a unit moving each of the divided files of distribution and arrangement between the plurality of peer nodes at a certain period of time. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a blade for a gas turbine, and more specifically, to the cooling of a gas turbine blade shroud.
[0002] A gas turbine is typically comprised of a compressor section, a combustor section and a turbine section. The compressor section produces compressed air. Then fuel is mixed with some of the compressed air and burned in the combustor section. The compressed, high temperature gas produced in the combustor section is then expanded through rows of stationary vanes and rotating blades in the turbine section to produce power in the form of a rotating shaft.
[0003] Each of the rotating blades has an airfoil portion and a root portion that connects it to a rotor. Since the blades are exposed to the compressed, hot gas discharging from the combustor section, the turbine blades must be cooled to prevent failure. Usually this cooling is done by taking a portion of the compressed air produced by the compressor and using it as cooling air in the turbine section to cool turbine blades. The cooling air enters each cooled turbine blade through its root, and flows through radial passageways in the airfoil portion of the blades. While in many cooled turbine blades, the radial passageways discharge the cooling air radially outward at the blade tip, some turbine blades incorporate shrouds that project outwardly from the airfoil at the blade tip. These shrouds prevent hot gas leakage past the blade tips, and may also be used to dampen blade vibration that tends to occur during normal operation of gas turbine engines. Unfortunately, excessive creep and creep failures can occur in blade shrouds due to the high operating temperatures.
[0004] While the known methods of cooling turbine blades are generally successful at cooling the airfoil portions of turbine blades, designs for cooling shrouds have produced mixed results. In some designs, cooling air discharged from the radial passages at the blade tip flows over the radially outward facing surface of the shroud. Although this provides some cooling, it is often insufficient to adequately cool the shroud due to heating of the cooling air in the airfoil passageways.
[0005] Another design includes incorporating cooling passages into each shroud, with the cooling passages extending approximately parallel to the radially inward facing surface of the shroud. These passages, which connect to one or more of the radial passageways, divert cooling air from the airfoil passageways so that it flows through the cooling passages in the shroud, thereby lowering the operating temperature of the shroud. While this method of internally cooling the shroud is generally more effective than flowing cooling air over the radially outward facing surface of the shroud, the heat transfer rate from the shroud to the cooling air in the passages may be insufficient to prevent excessive creep at certain operating conditions.
[0006] What is needed is a turbine blade having a shroud that is sufficiently cooled to prevent excessive creep at all engine operating conditions.
SUMMARY AND OBJECTS OF THE INVENTION
[0007] It is therefore an object of the present invention to provide a turbine blade having a shroud that is sufficiently cooled at all engine operating conditions to prevent the excessive creep that can occur in turbine shrouds when turbine blades are exposed to high stress and very high operating temperatures.
[0008] According to the preferred embodiment of the present invention, a turbine blade is disclosed having a root portion with a cooling fluid cavity therein, a platform connected to the root portion, an airfoil portion extending from the platform, the airfoil portion includes at least one cooling passageway extending substantially radially through the airfoil, and at least one cooling hole extending substantially radially through the airfoil, with the one cooling passageway and the cooling hole each defined by an inner wall having an inlet for receiving a flow of cooling fluid from the cavity. The turbine blade further includes a shroud projecting outwardly from the airfoil and has a radially inward facing surface, a radially outward facing surface, and a shroud edge extending therebetween, at least one cooling fluid outlet adjacent the edge, and at least one cooling passage between the radially inward facing surface and the radially outward facing surface. The cooling passage is approximately parallel to the radially inward facing surface, and a tube is located within the cooling hole. The tube has an outer wall, a first end adjacent the inlet and a second end radially outward therefrom. The cooling passage communicates with the inlet through the tube, and standoff means between the inner wall of the cooling passageway and the outer wall of the tube maintain the inner wall of said cooling passageway in spaced relation to said outer wall of the tube to minimize heat transfer between the airfoil and the tube.
[0009] The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0010] [0010]FIG. 1 shows a turbine blade of the present invention, with certain features shown in phantom lines.
[0011] [0011]FIG. 2 shows a cross-sectional view of the airfoil portion of the present invention taken along line A-A of FIG. 1.
[0012] [0012]FIG. 3 shows a cross-sectional view of a cooling passageway and tube taken along line B-B of FIG. 2.
[0013] [0013]FIG. 4 is a plan view of the shroud of the present invention showing the cooling passageways, cooling passages, and cooling fluid outlets.
[0014] [0014]FIG. 5 shows a cross-sectional view of the shroud of the present invention taken along line C-C of FIG. 4.
[0015] [0015]FIG. 6 is a cross-sectional view similar to FIG. 3, showing a first alternate embodiment of the present invention.
[0016] [0016]FIG. 7 is a cross-sectional view similar to FIG. 3, showing a second alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The present invention is relates to cooled turbine blades of the type used in gas turbine engines in which cooling air is supplied by the compressor of the gas turbine and is directed into the root of the cooled turbine blades through the rotors. These methods of getting the compressed air to the turbine blade roots will not be addressed in this description since these methods are well known in the art.
[0018] As shown in FIG. 1, the turbine blade 10 of the present invention includes a root portion 12 having a cooling fluid cavity 14 therein. A platform 16 is connected to the root portion, and an airfoil portion 18 extends away from from the platform 16 in a direction that is substantially parallel to a first radial direction 20 . The airfoil portion 18 includes at least one, and preferably a plurality of cooling passageways 22 extending substantially radially through the airfoil portion 18 . Each cooling passageway 22 has an inlet 24 for receiving a flow of cooling fluid from the cavity 14 . In addition to the cooling passageways 22 , the airfoil 18 preferably includes cooling holes 26 extending substantially radially through the airfoil portion 18 . Each cooling hole 26 also has an inlet 28 for receiving a flow of cooling fluid from the cavity 14 . A shroud 30 extends outwardly from the airfoil 18 adjacent the end of the airfoil 18 opposite the platform 16 .
[0019] As shown in FIG. 2, a tube 32 is located within each cooling passageway 22 . By contrast, the cooling holes 26 do not contain insulating tubes, since this would necessarily impair their ability to cool the airfoil portion 18 of the turbine blade 10 . Each tube 32 has an outer wall 34 and an internal wall 36 .
[0020] Referring now to FIG. 3, each insulating tube 32 has a first end 38 adjacent the inlet 24 of the passageway 22 in which it is located. In the preferred embodiment, standoff means extend from the inner wall 42 of the cooling passageway 22 . The standoff means comprise at least one, and preferably a plurality of, protrusions 40 extending inwardly from the inner wall 42 of of the passageway 22 . Each protrusion 40 may be annular and therefore entirely encircle the tube 32 , or each protrusion 40 may be nearly a localized “bump”, which cooperates with other the other protrusions to maintain the relative position of the tube 32 in the cooling passageway 22 . Each protrusion 40 contacts the outer wall 34 of the tube 32 , thereby maintaining the inner wall 42 of the cooling passageway 22 in spaced relation to the outer wall 34 of the insulating tube 32 . As those skilled in the art will readily appreciate, minimizing the contact area between the tube 32 and the inner wall 42 minimizes heat transfer between the airfoil portion 18 and the insulating tube 32 .
[0021] As shown in FIG. 4, the shroud 30 preferably has a “Z-notch” configuration of the type known in the art. Each shroud 30 includes at least one, and preferably a plurality of cooling passages 44 . Each cooling passage 44 has a cooling fluid outlet 46 adjacent an edge 48 that forms a portion of the Z-notch. Each cooling passage 44 communicates with an inlet 24 through one of the tubes 32 . As shown in FIG. 5, each shroud 30 has a radially inward facing surface 50 , a radially outward facing surface 52 , and a shroud edge 48 extending therebetween. Each cooling passage 44 is located between the radially inward facing surface 50 and the radially outward facing surface 52 . The cooling passages 44 are approximately parallel to the radially inward facing surface 50 .
[0022] Each tube 32 has a second end 54 radially outward from the first end 38 thereof. The second end 54 abuts a tube retention plug 56 . The tube retention plug 56 has an internal flowpath 58 , including a flowpath inlet 59 and at least one flowpath outlet 60 . The second end 54 of the tube 32 is preferably sealingly fixed to the tube retention plug 56 at the flowpath inlet 59 . Each cooling passage 44 is in fluid communication with one of the tubes 32 through the internal flowpath 58 of one of a tube retention plug 56 . The internal flowpath preferably includes metering means 62 for restricting fluid flow from the tube 32 to each cooling passage 44 .
[0023] As shown in FIG. 4, the preferred embodiment of the present invention has at least two cooling passageways 22 and a plurality of cooling passages 44 . Although the cooling fluid outlet 46 is shown in in the radially outward facing surface 52 of FIG. 5, it is to be understood that the cooling fluid outlet 46 may be located in the shroud edge 48 if it is desirable to flow cooling fluid into the gap 64 between the shrouds of adjacent turbine blades 10 . Likewise, if film cooling is desired along the edge 48 at the radially inward facing surface 50 , the cooling fluid outlet 46 may be located in the radially inward facing surface 50 immediately adjacent the edge 48 .
[0024] [0024]FIG. 6 shows a first alternate embodiment of the present invention, which is similar to the design of the preferred embodiment, except that the standoff means are different and a flange may be added to the cooling tube 32 . In the first alternate embodiment, the inner wall 42 of the cooling passageway 22 is smooth, and at least one, and preferably a plurality of, protrusions 66 extend from the tube 32 and contact the inner wall 42 of the cooling passageway 22 . As those skilled in the art will readily appreciate, the protrusions 66 maintain that tube 32 in spaced relation to the inner wall 42 of the cooling passageway 22 , thereby minimizing heat transfer between the airfoil portion 18 and the tube 32 . If the protrusions 66 are not annular, cooling air may be able to pass between the inner wall 42 of the cooling passageway 22 and the tube 32 . Therefore, in the first alternate environment, it is preferable to provide an annular flange 68 at the inlet 24 to the cooling passageway 22 to direct the cooling air into the tube 32 , and prevent cooling air from flowing between the inner wall 42 of the cooling passageway 22 and the tube 32 .
[0025] [0025]FIG. 7 shows a second alternate embodiment of the present invention, which likewise is similar to the design of the preferred embodiment except for the standoff means and the cooling tube flange. As in the first alternate embodiment, the inner wall 42 of the cooling passageway 22 is smooth, and at least one, and preferably a plurality of, protrusions 70 extend from the tube 32 and contact the inner wall 42 of the cooling passageway 22 . In the second alternate embodiment, the protrusions 70 are preferably annular, so that each protrusion 70 acts to prevent the flow cooling air through the between the inner wall 42 of the cooling passageway 22 and the tube 32 . The second alternate embodiment also preferably includes a flange 72 that performs the same functions as the flange 68 in the first alternate embodiment. However, since each protrusion 70 in the second alternate embodiment impedes the flow of cooling air between the inner wall 42 of passageway 22 and the tube 32 , flange 72 is not as critical to the overall performance of the present invention. In fact, the flange 72 may be identical to the protrusions 70 .
[0026] Although the preferred embodiments of the present invention have been described with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | A turbine blade is disclosed having a tip shroud that includes internal passages through which cooling air is flowed to minimize creep. The cooling air is provided to the shroud through dedicated cooling passageways which include tube inserts that restrict the transfer of heat from the airfoil portion of the turbine blade to the cooling air within the tube as the cooling air passes through the airfoil portion. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a tire forming system for consistently forming a pneumatic tire from materials and a tire forming method using the system and, more detailedly, relates to a tire forming system and a tire forming method, which facilitate a stage switchover of tires different in specification and make it possible to greatly increase a production efficiency of the tire.
In the pneumatic tire, there are many sizes owing to differences in oblate ratio and tread width even if bead inner diameters are the same. Further, even if the tire sizes are the same, there is the fact that kinds of compounds and the like are finely assorted in compliance with use objects.
In case of forming such many and various pneumatic tires, setting conditions of a forming machine for the tire size can be almost automatically changed at present, but a lot of time is required in a stage switchover of members supplied to the forming machine. Therefore, hitherto it is adapted such that the members for every tire size are preliminarily prepared, these members are supplied to a forming process and collected in a lot unit for every tire size to assemble unvulcanized tires. That is, in the tire forming process, by increasing the number of tires in one lot, the stage switchover operation is reduced, so that it becomes possible to increase a productivity.
However, a vulcanizing cycle time consumed for vulcanizing one tire is about 5 to 10 times a forming cycle time consumed for forming one tire, so that a correspondence of one to one has been impossible. Therefore, even if tires of specified size are continuously formed in a lot unit, it is impossible to use metal molds for vulcanizing the tires of specified size in agreement with the forming cycle time and, as a result, the unvulcanized tires stagnate as intermediate goods in process, i.e., a lead time increases, so that the production efficiency has been reduced.
Further, in case where, like the prior art, the members for every tire size are preliminarily prepared and these members are supplied to a forming process, it is indispensable to prepare and stock many intermediate members in compliance with many and various pneumatic tires. Therefore, material expenses and management costs of the intermediate members increase, so that a production cost of the tire has been raised.
SUMMARY OF THE INVENTION
An object of the invention is to provide a tire forming system and a tire forming method, which facilitate a stage switchover of tires different in specification and make it possible to greatly increase a production efficiency of the tire.
In order to achieve the above object, the invention provides a tire forming system including a band forming machine, a shaping forming machine and a belt/tread forming machine, in each of which setting conditions of a tire size can be optionally changed, and having transport means for delivering a semi-fabricated product to each forming machine, wherein as means for supplying a band member there are provided:
(1) inner liner supply means for cutting a sheet-like inner liner material having a width, in which a splice margin is added to a band periphery length, to a length corresponding to a specification width of a formed tire, and supplying the cut inner liner to the band forming machine;
(2) carcass supply means for cutting a sheet-like carcass material having a width, in which a splice margin is added to a band periphery length, to a length corresponding to a specification width of the formed tire, and supplying the cut carcass to the band forming machine;
(3) band rubber parts supply means for injecting a rubber strip from an injection unit, winding the rubber strip around a drum of the band forming machine, and forming, on the basis of its laminated structure, a rubber parts having a profile corresponding to a specification of the formed tire; and
(4) bead supply means for supplying a completed bead corresponding to a specification of the formed tire to the band forming machine through a bead setter; and
as means for supplying a belt/tread member there are provided:
(5) belt supply means for cutting a strip-like belt material, in which plural cords are arranged and rubberized, to predetermined length and angle, mutually splicing edge portions of the plural cut strip pieces to form a belt for one tire, which has a length, a cord angle and a width corresponding to specifications of the formed tire, and supplying the belt to the belt/tread forming machine; and
(6) tread rubber parts supply means for injecting a rubber strip from an injection unit, winding the rubber strip around a drum of the belt/tread forming machine, and forming, on the basis of its laminated structure, a rubber parts having a profile corresponding to a specification of the formed tire.
In the tire forming system in which the setting conditions of the tire size can be optionally changed in this manner, in regard to the tire having a specified band periphery length, since the supply means for all parts are constituted so as to be optionally set in compliance with the specification of the formed tire, it is possible to instantaneously perform the stage switchover so long as the tire has the same bead inner diameter, so that it is possible to continuously form the tires different in specification in one unit. Incidentally, the specification of the formed tire means tire forming conditions including a tire size, a thickness of rubber parts, a profile of tire, and the like.
And, if it becomes possible to form the tires different in specification in one unit, since it becomes null that unvulcanized tires waiting for being vulcanized in a specified metal mold are accumulated, it is possible to improve an operating efficiency of the metal mold, thereby reducing the goods in process of the unvulcanized tires. Further, in the above tire forming system, since parts preparation process is connected to each forming machine, it is possible to reduce the goods in process of intermediate members. As a result, it becomes possible to reduce costs of the goods in process, a management and auxiliary members, so that it becomes possible to greatly increase the production efficiency of the tire and, additionally, manufacture the tire stable in its quality.
In the invention, as the sheet-like inner liner and carcass materials, although one having the width in which the splice margin is added to the band periphery length is used, this width may be formed by a single sheet material, or may be formed by splicing plural sheet materials in their width direction. For example, in case where the inner liner and the carcass each having a width of about 50 inches are required, a sheet material having a width of about 50 inches may be used singly, or five sheet materials each having a width of about 10 inches may be bonded in parallel. However, in case where the plural sheet materials are used, it is necessary to take a splice margin between the sheets into consideration.
The aforesaid bead supply means is one for supplying the completed bead having a bead core and a bead filler which correspond to specifications of the formed tire and, more concretely, it is preferable that the bead supply means is constituted such that it holds plural kinds of completed beads each having a bead core corresponding to the band periphery length, selects the completed bead corresponding to the specification of the formed tire from the plural kinds of completed beads, and supplies the selected completed bead to the band forming machine through the bead setter. However, it may be constituted such that the bead core corresponding to the band periphery length is prepared, and on its outer periphery there is formed the bead filler corresponding to the specification of the formed tire.
Further, as the injection unit it is preferable to use a plunger type injection unit in which there is accommodated, for the respective rubber parts, a rubber amount corresponding at least to the specification of the formed tire. Such a plunger type injection unit can precisely inject a required volume of unvulcanized rubber for the respective rubber parts and, moreover, can easily change the require volume for every tire.
Further, in order to achieve the aforesaid object, the invention provides a tire forming method using a tire forming system including a band forming machine, a shaping forming machine and a belt/tread forming machine, in each of which setting conditions of a tire size can be optionally changed, and having transport means for delivering a semi-fabricated product to each forming machine, wherein as a process for supplying a band member there are provided:
(1) an inner liner supply process for cutting a sheet-like inner liner material having a width, in which a splice margin is added to a band periphery length, to a length corresponding to a specification width of a formed tire, and supplying the cut inner liner to the band forming machine;
(2) a carcass supply process for cutting a sheet-like carcass material having a width, in which a splice margin is added to a band periphery length, to a length corresponding to a specification width of the formed tire, and supplying the cut carcass to the band forming machine;
(3) a band rubber parts supply process for injecting a rubber strip from an injection unit, winding the rubber strip around a drum of the band forming machine, and forming, on the basis of its laminated structure, a rubber parts having a profile corresponding to a specification of the formed tire; and
(4) a bead supply process for supplying a completed bead corresponding to a specification of the formed tire to the band forming machine through a bead setter; and
as a process for supplying a belt/tread member there are provided:
(5) a belt supply process for cutting a strip-like belt material, in which plural cords are arranged and rubberized, to predetermined length and angle, mutually splicing edge portions of the plural cut strip pieces to form a belt for one tire, which has a length, a cord angle and a width corresponding to specifications of the formed tire, and supplying the belt to the belt/tread forming machine; and
(6) a tread rubber parts supply process for injecting a rubber strip from an injection unit, winding the rubber strip around a drum of the belt/tread forming machine, and forming, on the basis of its laminated structure, a rubber parts having a profile corresponding to a specification of the formed tire.
It is preferable that, in the above bead supply process, plural kinds of completed beads each having a bead core corresponding to the band periphery length are prepared, the completed bead corresponding to the specification of the formed tire is selected from the plural kinds of completed beads, and the selected completed bead is supplied to the band forming machine through the bead setter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a tire forming system according to an embodiment of the invention;
FIG. 2 is a side view showing, partially omitted, the tire forming system according to the embodiment of the invention;
FIG. 3 is a sectional view exemplifying a rubber servicer used in the invention;
FIG. 4( a ) to FIG. 4( d ) are sectional views of main portion, showing forming processes of a band member by the tire forming system of the invention;
FIG. 5( a ) to FIG. 5( d ) are sectional views of main portion, showing forming processes of a belt/tread member by the tire forming system of the invention;
FIG. 6( a ) to FIG. 6( b ) are sectional views of main portion, showing shaping processes by the tire forming system of the invention;
FIG. 7 is a plan view showing a tire forming system according to another embodiment of the invention; and
FIG. 8 is a side view showing, partially omitted, the tire forming system according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a plan view showing a tire forming system according to an embodiment of the invention, and FIG. 2 a side view of the same. However, in FIG. 2 , a part of constitution is omitted.
This system is a tire forming system including a band forming machine 10 , a shaping forming machine 20 and a belt/tread forming machine 30 , and having a band transfer 40 and a belt transfer 50 as transport means for delivering a semi-fabricated product to the respective forming machines 10 , 20 , 30 . Each of the band forming machine 10 , the shaping forming machine 20 and the belt/tread forming machine 30 is constituted such that setting conditions of a tire size can be optionally changed. Further, the band forming machine 10 , the band transfer 40 , the belt transfer 50 and the belt/tread forming machine 30 are arranged so as to be movable on one pair of left/right linearly laid rails 55 . The shaping forming machine 20 is arranged so as to be movable on one pair of left/right rails 56 intersecting the rails 55 .
The band forming machine 10 is provided on a carriage 12 having wheels 11 with a driving section 13 , and supports a band drum 14 such that its rotary shaft horizontally extends from the driving section 13 . The band drum 14 is constituted so as to be retractable in a drum radius direction by a drive of the driving section 13 . The carriage 12 is controlled in its position on the rails 55 by a control unit (not shown).
The shaping forming machine 20 is provided on a carriage 22 having wheels 21 with a driving section 23 , and supports the driving section 23 such that it extends from a rails 56 side to a region just above the rails 55 and a retractable driving shaft 25 having one pair of shaping drums 24 horizontally extends from the driving section 23 . One pair of shaping drums 24 are adapted such that a mutual spacing is variable by a retraction of the driving shaft 25 . Further, a bead clamp section of the shaping drum 24 is constituted so as to be retractable. The carriage 22 is controlled in its position on the rails 56 by a control unit (not shown).
The belt/tread forming machine 30 is provided on a carriage 32 having wheels 31 with a driving section 33 , and supports a forming drum 34 such that its rotary shaft horizontally extends from the driving section 33 . The forming drum 34 is constituted so as to be retractable in a drum radius direction by a drive of the driving section 33 . The carriage 32 is controlled in its position on the rails 55 by a control unit (not shown).
The band transfer 40 has a constitution in which one pair of left/right holding rings 43 for holding a band member in its cylindrical form intact and one pair of left/right bead setters 44 for holding completed beads to predetermined positions in an outer periphery side of the band member are provided on a carriage 42 having wheels 41 . The carriage 42 is controlled in its position on the rails 55 by a control unit (not shown).
The belt transfer 50 has a constitution in which a grip section 53 for gripping a belt/tread member from outside is provided on a carriage 52 having wheels 51 . The carriage 52 is controlled in its position on the rails 55 by a control unit (not shown).
In the tire forming system mentioned above, as means for supplying the band member, there are arranged an inner liner servicer 60 , a carcass servicer 70 , rubber parts servicers 80 and a bead servicer 90 .
The inner liner servicer 60 is adapted such that a long sheet-like inner liner material 61 having a width in which a splice margin is added to a specified band periphery length is held by a reel 62 , the inner liner material 61 unwound from the reel 62 is sent with a predetermined length unit by a conveyor 63 and cut by a cutter 64 to a length corresponding to a specification width of a formed tire, and thus an inner liner 65 having a necessary dimension is formed.
The carcass servicer 70 is adapted such that a long sheet-like carcass material 71 having a width in which a splice margin is added to a specified band periphery length is held by a reel 72 , the carcass material 71 unwound from the reel 72 is sent with a predetermined length unit by a conveyor 73 and cut by a cutter 74 to a length corresponding to a specification width of the formed tire, and thus a carcass 75 having a necessary dimension is formed.
That is, the inner liner servicer 60 and the carcass servicer 70 are adapted such that they can respectively supply the inner liner 65 and the carcass 75 which are used in a tire having the same bead inner diameter corresponding to the specified band periphery length, and the cut dimensions of the inner liner and the carcass can be changed in compliance with an oblate ratio and a tread width of the formed tire. The inner liner 65 and the carcass 75 are adapted so as to be sequentially supplied to the band forming machine 10 through a carrying conveyor 66 . The inner liner material 61 can be composed of a rubber and the like. Further, as the carcass material 71 , it is possible to use a calender material rubberized by pulling together plural cords along a sheet longitudinal direction.
The plural rubber parts servicers 80 are arranged in the vicinity of the band forming machine 10 such that compounds constituting the band member, such as a rim cushion, side walls and a belt edge cushion, correspond to different parts. Each of the rubber parts servicers 80 has an injection unit 82 extending from a hydraulic cylinder 81 toward the band forming machine 10 , and a feed extruder 83 is provided in a tip portion of the injection unit 82 . The rubber parts servicer 80 is constituted so as to be shiftable by a driving unit (not shown) to an optional position in axial and radial directions of the band drum 14 . And, the rubber parts servicer 80 is adapted such that a rubber strip injected from the injection unit 82 is wound around the band drum 14 to thereby form, on the basis of its laminated structure, the rubber parts for band having a profile corresponding to a specification of the formed tire.
More concretely, the above strip winding technique is adapted such that a desired profile is realized by bonding a tip of the rubber strip to the band drum 14 , rotating the band drum 14 while continuously injecting the rubber strip from the injection unit 82 , traversing the rubber parts servicers 80 along an axial direction of the band drum 14 , and controlling a rotating speed of the band drum 14 and traversing speeds of the rubber parts servicers 80 .
The bead servicer 90 is one for supplying a completed bead corresponding to a specification of the completed tire to the band forming machine 10 through the bead setter 44 . More concretely, the bead servicer 90 is adapted such that plural kinds of completed beads A to F are respectively held, while being classified by the kind, on plural holding arms 92 radially extending from a bead stocker 91 . Each of the completed beads A to F is one in which a bead core corresponding to the band periphery length and bead fillers of variously different shapes or compounds are combined. The bead stocker 91 is rotatable, and adapted such that one pair of completed beads corresponding to the specification of the formed tire are selected from the plural kinds of completed beads A to F, and the selected one pair of completed beads are delivered to a bead transfer 93 . The bead transfer 93 is extended to a region just above the band transfer 40 , and adapted such that the selected one pair of completed beads are supplied to the bead setter 44 through a delivering arm 94 .
In the above tire forming system, as means for supplying the belt/tread member, there are arranged a belt servicer 100 , and rubber parts servicers 110 .
The belt servicer 100 is adapted such that a cutter 102 extending in a conveyor carrying direction is arranged in an edge portion of a carrying conveyor 101 , and a strip-like belt material 103 is supplied onto the carrying conveyor 101 while being passed below the cutter 102 . The belt material 103 is transported by a conveyor 104 , and carried to a predetermined position on the carrying conveyor 101 while being guided by a splicer 105 having a guide function. A supplying angle of the belt material 103 with respect to a carrying direction of the carrying conveyor 101 is adapted so as to be changeable about a center axis O together with the conveyor 104 and the splicer 105 . Therefore, a cutting angle of the belt material 103 can be optionally selected on the basis of the supplying angle of the belt material 103 . On the other hand, a cut length of the belt material 103 can be optionally selected on the basis of a feeding amount of the conveyor 104 . Further, the belt material 103 is one rubberized by pulling together plural cords. Such a belt material 103 may be directly supplied from a calender unit or an insulation extruder, or may be supplied from a reel around which one formed by the calender unit or the insulation extruder has been once wound.
If the carrying conveyor 101 transports a strip piece 106 cut from the belt material 103 by a distance corresponding approximately to a strip width to a belt/tread forming machine 30 side, the further belt material 103 is supplied onto the carrying conveyor 101 . And, the splicer 105 mutually splices, in order, edge portions of the strip pieces 106 , 106 adjoining each other. By means of splicing integer number of strip pieces 106 by repeating such a process, it is possible to form a belt 107 for one tire having a length, a cord angle and a width, which correspond to specifications of the formed tire. On this occasion, in order to make the number of the strip pieces 106 an integer, it is preferable to cause the length of the belt 107 to agree with a specification belt length by adjusting a minute angle (within ±1°) with respect to a specification cord length of the formed tire. The belt 107 is supplied as it is to the belt/tread forming machine 30 through the carrying conveyor 101 .
The plural rubber parts servicers 110 are arranged in the vicinity of the belt/tread forming machine 30 such that compounds constituting the belt/tread member, such as an under tread and a cap tread, correspond to different parts. Each of the rubber parts servicers 110 has an injection unit 112 extending-from a hydraulic cylinder 111 toward the belt/tread forming machine 30 , and a feed extruder 113 is provided in a tip portion of the injection unit 112 . The rubber parts servicer 110 is constituted so as to be shiftable by a driving unit (not shown) to an optional position in axial and radial directions of the forming drum 34 . And, the rubber parts servicer 110 is adapted such that a rubber strip injected from the injection unit 112 is wound around the forming drum 34 to thereby form, on the basis of its laminated structure, the rubber parts for tread consisting of a profile corresponding to a specification of the formed tire.
More concretely, the above strip winding technique is adapted such that a desired profile is realized by bonding a tip of the rubber strip to the forming drum 34 , rotating the forming drum 34 while continuously injecting the rubber strip from the injection unit 112 , traversing the rubber parts servicers 110 along an axial direction of the forming drum 34 , and controlling a rotating speed of the forming drum 34 and traversing speeds of the rubber parts servicers 110 .
As the aforesaid injection unit of the rubber parts servicers 80 , 110 , it is preferable to use a plunger type injection unit accommodating a rubber amount corresponding, for the respective rubber parts, at least to a specification of the formed tire. FIG. 3 exemplifies the rubber parts servicer using the plunger type injection unit. As shown in FIG. 3 , a plunger type injection unit 120 has a constitution in which a plunger 122 is slidably provided inside a cylindrical injection pot 121 and the plunger 122 is moved back and forth by a piston cylinder 124 extending from a hydraulic cylinder 123 , and is adapted such that an unvulcanized rubber accommodated in the injection pot 121 is injected from a die 125 . The plunger type injection unit 120 has advantages that it can precisely inject the unvulcanized rubber in a volume necessary for the respective rubber parts and, moreover, can easily change a volume of the compounds necessary for every one tire.
Further, as means for pouring the unvulcanized rubber into the plunger type injection unit 120 , it is preferable to use a screw type feed extruder 130 . The screw type feed extruder 130 has a constitution in which a screw 132 is rotatably provided inside a cylindrical cylinder 131 and the screw 132 is driven to rotate by a hydraulic motor 133 , and is adapted such that the unvulcanized rubber supplied from a rubber supply section 134 is moved by a rotation of the screw 132 to feed it from a discharge port 135 into the injection pot 121 of the injection unit 120 . The discharge port 135 of the feed extruder 130 is connected to an input port 126 provided in the injection pot 121 . Further, a check valve 136 for regulating a flow of the unvulcanized rubber in one direction is provided in the discharge port 135 . When feeding to the injection unit 120 , the plunger 122 of the injection unit 120 is retracted by pouring the unvulcanized rubber from the feed extruder 130 into the injection pot 121 of the injection unit 120 .
Further, it is preferable that dimensions of a rubber strip injected from the injection unit 120 are made 0.5 to 3.0 mm in thickness and 5 to 30 mm in width. If these dimensions are too small it becomes difficult to efficiently form the tire and, reversely, if they are too large an accuracy of a profile of the rubber parts is deteriorated.
Next, it is detailedly explained about a tire forming method using the tire forming system mentioned above.
FIG. 4( a ) to FIG. 4( d ) show forming processes of the band member. In the forming processes of a band member 140 , the band drum 14 is first disposed to a position facing the rubber parts servicers 80 by moving the band forming machine 10 on the rails 55 . And, the desired compounds are accommodated, for the respective rubber parts, in the injection units 82 of the rubber parts servicers 80 , corresponding to the rim cushion and the side wall, and the rubber strips supplied from the injection units 82 are wound around the band drum 14 while controlling the rotating speed of the band drum 14 and the traversing speeds of the rubber parts servicers 80 . In this manner, a side wall 141 shown in FIG. 4( a ) is formed at a position, in the band drum 14 , corresponding to the specification of the formed tire and, additionally, a rim cushion 142 shown in FIG. 4( b ) is formed.
Next, the desired compounds are accommodated, for the respective rubber parts, in the injection unit 82 of the rubber parts servicers 80 , corresponding to the belt edge cushion, and the rubber strip supplied from the injection unit 82 is wound around a predetermined position of the carcass 75 on the band drum 14 while controlling the rotating speed of the band drum 14 and the traversing speed of the rubber parts servicer 80 . In this manner, a belt edge cushion 143 shown in FIG. 4( d ) is formed at a position corresponding to the specification of the formed tire.
Next, the desired compounds are accommodated, for every parts, in the injection unit 82 of the rubber parts servicers 80 , corresponding to the belt edge cushion, and the rubber strip supplied from the injection unit 82 is wound around a predetermined position of the carcass 75 on the band drum 14 while controlling the rotating speed of the band drum 14 and the traversing speed of the rubber parts servicer 80 . In this manner, a belt edge cushion 143 shown in FIG. 4( d ) is formed at a position corresponding to the specification of the formed tire.
On the other hand, the bead servicer 90 selects one kind of completed bead corresponding to the specification of the formed tire from the plural kinds of completed beads A to F, and they are set to the bead setter 44 of the band transfer 40 .
Next, as shown in FIG. 4( d ), one pair of left/right completed beads 144 are disposed on an outer periphery side of the band drum 14 by moving the band transfer 40 on the rails 55 . And, one pair of left/right completed beads 144 are fixed to the band member 140 wound around the band drum 14 by slightly expanding the band drum 14 in its diameter. And, the band transfer 40 is moved on the rails 55 while holding the band member 140 in its cylindrical form by the holding rings 43 of the band transfer 40 , and the band member 140 is carried to the shaping forming machine 20 .
FIG. 5( a ) to FIG. 5( d ) show forming processes of the belt/tread member. In the forming processes of a belt/tread member 150 , the forming drum 34 is first disposed to a position facing the carrying conveyor 101 of the belt servicer 100 by moving the belt/tread forming machine 30 on the rails 55 . And, a 1st belt 151 and a 2nd belt 152 , for one tire, which have lengths, cord angles and widths corresponding to the specifications of the formed tire are supplied from the belt servicer 100 . In this manner, the 1st belt 151 is wound around the forming drum 34 as shown in FIG. 5( a ) and, additionally, the 2nd belt 152 is wound as shown in FIG. 5( b ). As occasion demands, rubber tapes may be wound on both end portions of the 1st belt 151 , or a jointless belt reinforcing layer may be wound on the 2nd belt 152 .
Next, the forming drum 34 is disposed to a position facing the rubber parts servicers 110 by moving the belt/tread forming machine 30 on the rails 55 . And, desired compounds are accommodated in the injection unit 112 of the rubber parts servicer 110 for the under tread, and the rubber strip supplied from the injection unit 112 is wound around the forming drum 34 while controlling the rotating speed of the forming drum 34 and the traversing speed of the rubber parts servicer 110 . In this manner, an under tread 153 shown in FIG. 5( c ) is formed around the forming drum 34 . Then, desired compounds are accommodated in the injection unit 112 of the rubber parts servicer 110 for the cap tread, and a cap tread 154 shown in FIG. 5( d ) is formed by the rubber strip winding on the basis of a control similar to the above.
Next, the belt transfer 50 is moved on the rails 55 and the grip section 53 is disposed to an outer periphery side of the forming drum 34 . Then, after gripping the belt/tread member 150 by the grip section 53 , by slightly contracting the forming drum 34 in its diameter, the belt/tread 150 is held by the grip section 53 . And, the belt/tread member 150 is carried to the shaping forming machine 20 by moving the belt transfer 50 on the rails 55 . Incidentally, when carrying the belt/tread member 150 to the shaping forming machine 20 , the shaping forming machine 20 is preliminarily moved on the rails 56 so as to deviate from an orbit of the belt transfer 50 .
FIG. 6( a ) to FIG. 6( b ) show shaping processes. In the shaping processes, as shown in FIG. 6( a ), the band member 140 is mounted by expanding one pair of left/right shaping drums 24 of the shaping forming machine 20 in their diameters. And, as shown in FIG. 6( b ), a carcass end portion of the band member 140 is rolled up around the bead while exerting a pressure from an inside of the band member 140 , and the band member 140 is expanded in its diameter by narrowing a mutual spacing of the shaping drums 24 , thereby integrating the band member 140 and the belt/tread member 150 . Further, in order to strengthen a bonded state between the integrated band member 140 and the belt/tread member 150 , a bonded portion may be worked by a stretcher and the like.
In the above tire forming system, so long as the tire has the same bead inner diameter, the stage switchover can be performed instantaneously. For example, as to the inner liner 65 and the carcass 75 , the stage switchover is completed merely by changing the cutting lengths of the inner liner servicer 60 and the carcass servicer 70 . As to the rubber parts for band, such as the side wall 141 , the rim cushion 142 and the belt edge cushion 143 , the stage switchover is completed merely by changing the setting of the rubber parts servicer 80 . As to the completed bead 144 , the stage switchover is completed merely by changing the selection of the bead servicer 90 . As to the belt such as the 1 st belt 151 and the 2 nd belt 152 , the stage switchover is completed merely by changing the setting of the belt servicer 100 . As to the rubber parts for tread, such as the under tread 153 and the cap tread 154 , the stage switchover is completed merely by changing the setting of the rubber parts servicer 110 . And, since each of the above stage switchovers can be performed by means of an automatic control by a computer and the like, the stage switchovers of the whole system can be automatically performed instantaneously. As a result, the tire whose bead inner diameter is the same but which is different in its tire size, use and characteristics can be continuously formed in one unit.
In this manner, if it becomes possible to form the tires different in specification in one unit, such a fact becomes null that the unvulcanized tires waiting for being vulcanized in a specified metal mold are accumulated. For example, if six kinds of tires corresponding to the completed beads A to F are formed in order, since it is possible to supply in order the unvulcanized tires to six kinds of metal molds, it is possible to reduce the lead time by causing the forming cycle time to agree with the vulcanizing cycle time, thereby reducing the goods in process of the unvulcanized tires.
Further, in the above tire forming system, since the parts preparation process is connected respectively to the band forming machine 10 and the belt/tread forming machine 30 , it is possible to nullify the goods in process of the intermediate members other than the completed beads A to F.
Accordingly, if the forming of the pneumatic tire is performed by the above tire forming system, it becomes possible to reduce costs of the goods in process, a management and auxiliary members, so that it becomes possible to greatly increase a production efficiency of the tire and manufacture the tire stable also in its quality.
FIG. 7 is a plan view showing a tire forming system according to another embodiment of the invention, and FIG. 8 is a side view of the same. However, in FIG. 8 , a part of the constitution is omitted. This embodiment is one in which only the band forming machine 10 and the belt/tread forming machine 30 are differentiated from the aforesaid embodiment, so that the same reference numeral is given to the same component as FIG. 1 and FIG. 2 , and the detailed explanation of that component is omitted.
The band forming machine 10 has two band drums 14 a , 14 b in front and rear of the driving section 13 . The driving section 13 is connected to a reversing unit 16 through a horizontally extending support shaft 15 . The reversing unit 16 is adapted so as to rotate the driving section 13 around the support shaft 15 , thereby replacing positions of the two band drums 14 a , 14 b . Further, the carrying conveyor 66 and the rubber parts servicers 80 are arranged in positions respectively facing the two band drums 14 a , 14 b.
In this manner, by providing the band forming machine 10 with the two band drums 14 a , 14 b to constitute such that both are interchangeable, it becomes possible to perform a forming operation of the rubber parts for band by one band drum 14 b while performing a winding operation of the inner liner and the carcass by the other band drum 14 a , so that it is possible to further increase the production efficiency of the tire.
On the other hand, the belt tread forming machine 30 has two forming drums 34 a , 34 b in front and rear of the driving section 33 . The driving section 33 is connected to a reversing unit 36 through a horizontally extending support shaft 35 . The reversing unit 36 is adapted so as to rotate the driving section 33 around the support shaft 35 , thereby replacing positions of the two forming drums 34 a , 34 b . Further, the carrying conveyor 101 and the rubber parts servicers 110 are arranged in positions respectively facing the two forming drums 34 a , 34 b.
In this manner, by providing the belt/tread forming machine 30 with the two band drums 34 a , 34 b to constitute such that both are interchangeable, it becomes possible to perform a forming operation of the rubber parts for tread by one forming drum 34 b while performing a winding operation of the belt by the other forming drum 34 a , so that it is possible to further increase the production efficiency of the tire.
In the invention, as to the band forming machine, the shaping forming machine and the belt/tread forming machine, although it is required that setting conditions of the tire size can be optionally changed, a concrete constitution therefor is not limited specifically, and it is possible to adopt an optional expansion/contraction mechanism or retractable mechanism, and the like.
As explained above, according to the invention, in the tire forming system capable of optionally changing the setting conditions of the tire size, since it is constituted such that, in regard to the formed tire having the specified band periphery length, the supply means of all parts can be optionally set in compliance with the specification of the formed tire, it is possible to perform the stage switchover instantaneously so long as the tire has the same bead inner diameter, so that it is possible to continuously form the tires different in specification in one unit. Further, since the parts preparation process is connected to each forming machine, it is possible to reduce the goods in process of the intermediate members.
Accordingly, if the tire forming system of the invention is adopted, in comparison with the prior art, it becomes possible to reduce costs of the goods in process, a management and auxiliary members, so that it becomes possible to greatly increase the production efficiency of the tire and manufacture the tire stable also in its quality. | A tire forming system includes a band forming machine, a shaping forming machine, a belt/tread forming machine, means for supplying a band member and means for supplying a belt/tread member. The means for supplying the band member include an inner liner supply means, carcass supply means, band rubber parts supply means and bead supply means. The means for supplying the belt/tread member include belt supply means and tread rubber parts supply means. The means for supplying the band member and the means for supplying the belt/tread member are operative to cooperate with one another to continuously in series form a plurality of tires having different tire sizes. | 1 |
FIELD OF THE INVENTION
The present invention relates to a process for preparing a compound, in particular, to a process for preparing trifluorochloroethylene.
TECHNICAL BACKGROUND OF THE INVENTION
Trifluorochloroethylene (CTFE) is an important special monomer for fluorine-containing high performance materials in which polytrifluorochloroethylene has superior oxygen isolating and low temperature resistant properties and thus is widely used in packaging films for medicine, electronics encapsulation applications and delivery tubes for low temperature materials. Additionally, fluorine-containing coatings with trifluorochloroethylene as the main monomer have superior weather resistant and corrosion resistant properties, and are widely used in building industries. Currently, the global annual output of trifluorochloroethylene is around 10,000 tons, and the primary process for preparing the same is to dechlorine from trifluorotrichloroethane with the action of zinc powder or hydrogen.
Since in the conventional process significant amount of zinc powder will be consumed when zinc powder is used for dechlorination, and meanwhile significant amount of zinc chloride waste residues will be generated, the production cost of trifluorochloroethylene would be increased a lot due to consumption of zinc powder and the need of treatment of the residues. When hydrogen is directly used for dechlorination, an expensive rare metal such as platinum, rhodium or ruthenium would be required as a catalyst, and therefore, the production cost is also relatively high. Meanwhile, hydrogenation by using hydrogen directly tends to result in excessive hydrogenation, and impurities such as trifluoroethylene may be generated, which would result in decrease of yield and purity of the product. The disadvantages of the processes disclosed in patent documents U.S. Pat. No. 2,685,606, U.S. Pat. No. 2,704,777, EP 0416015 and U.S. Pat. No. 3,333,011 have been summarized as above. Generally, the product cost of trifluorochloroethylene in these documents is relatively high, and the yield of product is relatively low, typically only about 85%.
SUMMARY OF THE INVENTION
The technical problem solved by the present invention is to provide a process for preparing trifluorochloroethylene, which is green, of low cost but high yield. In order to solve the above technical problem, the technical solution provided in the present invention is as follows:
A new green process for preparing trifluorochloroethylene comprising: in a multi-tubular reactor, hydrogenation reacting 1,1,2-trifluoro-1,2,2-trichloroethane directly with a catalyst potassium zinc trihydride to obtain trifluorochloroethylene, with the following chemical equation:
3CF 2 ClCCl 2 F+KZnH 3 →3ClFC=CF 2 +KZnCl 3 +3HCl,
wherein the catalytic reaction is performed at a temperature of 250-350° C. and a pressure of 0.7-1.0 MPa for 10-20 seconds.
The catalyst can be reused upon activation by addition of hydrogen, and a process for activating the catalyst comprising: activating the catalyst with the action of hydrogen, with the following chemical equation:
KZnCl 3 +3H 2 →KZnH 3 +3HCl,
wherein the activating is performed at a temperature of 200-300° C. and a pressure of 0.9-1.0 MPa for 5-10 seconds.
A process for preparing the catalyst potassium zinc trihydride comprising: dissolving potassium chloride in an deionized water to obtain a potassium chloride solution; dissolving zinc chloride in an deionized water to obtain a zinc chloride solution; adding dropwise the zinc chloride solution to the potassium chloride solution and reacting at 50-80° C. and atmosphere pressure for 5-10 hours to obtain a potassium zinc trihydride solution; evaporating the potassium zinc trihydride solution to obtain potassium zinc trihydride; treating the potassium zinc trihydride by hydrogenation directly using hydrogen, wherein the molar ratio of potassium zinc trihydride to hydrogen is 1:3 to 1:4, the temperature of the hydrogenation is 200-300° C., the reaction pressure is 0.9-1.0 MPa, and the reaction time is 5-10 seconds; the concentration of the potassium chloride solution is 20-32% by weight, the concentration of the zinc chloride is 50-82% by weight, and the conductivity of the deionized water is 0.01-0.02μ.
The conventional process in which zinc powder is used for dechlorination or hydrogen is used for dechlorination through hydrogenation with the action of a noble metal catalyst is avoided in the process of the present invention. The present process substantially reduces the production cost of trifluorochloroethylene, and substantially increases the product yield, which can be up to 99% or more.
DETAILED DESCRIPTION OF THE INVENTION
The products obtained in the Examples of the present invention were measured by a gas chromatography/mass-spectrography 6890N/5937 (GC/MS) from Agilent.
Potassium zinc trihydride is prepared using the following method: potassium chloride is dissolved in an deionized water (the conductivity of the deionized water is 0.01-0.02μ) to obtain a potassium chloride solution (the concentration of the potassium chloride solution is 20-32% by weight); zinc chloride is dissolved in an deionized water (the conductivity of the deionized water is 0.01-0.02μ) to obtain a zinc chloride solution (the concentration of the zinc chloride is 50-82% by weight); add dropwise the zinc chloride solution to the potassium chloride solution and have them react at 50-80° C. and atmosphere pressure for 5-10 hours to obtain a potassium zinc trihydride solution; the potassium zinc trihydride solution is subjected to evaporation to obtain potassium zinc trihydride; the potassium zinc trihydride is then subjected to a hydrogenation treatment, wherein the molar ratio of potassium zinc trihydride to hydrogen us 1:3 to 1:4, the temperature of the hydrogenation is 200-300° C., the reaction pressure is 0.9-1.0 MPa, and the reaction time is 5-10 seconds.
Example 1
21.4 Kg potassium zinc trihydride was placed in a multi-tubular reactor comprising six nickel alloy tubes each having a diameter of 40 mm and a length of 6,000 mm, and the catalyst was added in a volume of 30 L. The multi-tubular reactor jacket was heated with a thermal oil. The reactor was heated up to 250° C., and nitrogen was introduced at a rate of 10 L/min to further dry the catalyst. The introduction of nitrogen was continued for 5 hours, and then the reactor was further heated up to 300° C. 1,1,2-trifluo-1,2,2-trichloroethane was preheated and then fed into the multi-tubular reactor from the top thereof, with the feeding rate under standard state being 180 L/min. The pressure of the multi-tubular reactor was maintained at 0.8 MPa. The reacted materials were then discharged from the bottom of the multi-tubular reactor, washed directly with water and alkali, dried with a molecular sieve, condensed, collected by rectification, and then samples were taken and analyzed. After an hour, 56 Kg trifluorochloroethylene having a purity of 99.5% was obtained. The conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane was 99.0%, and the yield was 99.20%.
When the conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane and the yield began to decrease, stop feeding and began to feed hydrogen, with the temperature of the multi-tubular reactor being maintained at 300° C., the feeding rate of hydrogen under standard state being 360 L/min, and the pressure of the multi-tubular reactor being maintained at 0.9 MPa. After 30 minutes, the activation was completed, and the feeding was switched back. The feeding rate of 1,1,2-trifluo-1,2,2-trichloroethane was 180 L/min under standard state, and the pressure of the multi-tubular reactor was maintained at 0.8 MPa. The reacted materials were then discharged from the bottom of the multi-tubular reactor, washed directly with water and alkali, dried with a molecular sieve, condensed, collected by rectification, and then samples were taken and analyzed. After an hour, 55.9 Kg trifluorochloroethylene having a purity of 99.5% was obtained. The conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane was 99.1%, and the yield was 99.02%.
Example 2
21.4 Kg potassium zinc trihydride was placed in a multi-tubular reactor comprising six nickel alloy tubes having a diameter of 40 mm and a length of 6,000 mm, and the catalyst was added in a volume of 30 L. The multi-tubular reactor jacket was heated with a thermal oil. The reactor was heated up to 250° C., and nitrogen was introduced at a rate of 10 L/min to further dry the catalyst. The introduction of nitrogen was continued for 5 hours, and then the reactor was further heated up to 280° C. 1,1,2-trifluo-1,2,2-trichloroethane was preheated and then fed into the multi-tubular reactor from the top thereof, with the feeding rate under standard state being 120 L/min. The pressure of the multi-tubular reactor was maintained at 0.9 MPa. The reacted materials were then discharged from the bottom of the multi-tubular reactor, washed directly with water and alkali, dried with a molecular sieve, condensed, collected by rectification, and then samples were taken and analyzed. After an hour, 37.25 Kg trifluorochloroethylene having a purity of 99.60% was obtained. The conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane was 99.2%, and the yield was 99.07%.
When the conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane and the yield began to decrease, stop feeding and began to feed hydrogen, with the temperature of the multi-tubular reactor being maintained at 280° C., the feeding rate of hydrogen under standard state being 240 L/min, and the pressure of the multi-tubular reactor being maintained at 1.0 MPa. After 30 minutes, the activation was completed, and the feeding was switched back. The feeding rate of 1,1,2-trifluo-1,2,2-trichloroethane was 120 L/min under standard state, and the pressure of the multi-tubular reactor was maintained at 0.9 MPa. The reacted materials were then discharged from the bottom of the multi-tubular reactor, washed directly with water and alkali, dried with a molecular sieve, condensed, collected by rectification, and then samples were taken and analyzed. After an hour, 37.22 Kg trifluorochloroethylene having a purity of 99.70% was obtained. The conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane was 99.2%, and the yield was 99.09%.
Example 3
21.4 Kg potassium zinc trihydride was placed in a multi-tubular reactor comprising six nickel alloy tubes having a diameter of 40 mm and a length of 6,000 mm, and the catalyst was added in a volume of 30 L. The multi-tubular reactor jacket was heated with a thermal oil. The reactor was heated up to 250° C., and nitrogen was introduced at a rate of 10 L/min to further dry the catalyst. The introduction of nitrogen was continued for 5 hours, and then the reactor was further heated up to 320° C. 1,1,2-trifluo-1,2,2-trichloroethane was preheated and then fed into the multi-tubular reactor from the top thereof, with the feeding rate under standard state being 90 L/min. The pressure of the multi-tubular reactor was maintained at 1.0 MPa. The reacted materials were then discharged from the bottom of the multi-tubular reactor, washed directly with water and alkali, dried with a molecular sieve, condensed, collected by rectification, and then samples were taken and analyzed. After an hour, 27.90 Kg trifluorochloroethylene having a purity of 99.9% was obtained. The conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane was 99.5%, and the yield was 99.22%.
When the conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane and the yield began to decrease, stop feeding and began to feed hydrogen, with the temperature of the multi-tubular reactor being decreased to 300° C., the feeding rate of hydrogen under standard state being 180 L/min, and the pressure of the multi-tubular reactor being maintained at 0.9 MPa. After 30 minutes, the activation was completed, and the feeding was switched back. The feeding rate of 1,1,2-trifluo-1,2,2-trichloroethane was 90 L/min under standard state, and the pressure of the multi-tubular reactor was maintained at 1.0 MPa. The reacted material was then discharged from the bottom of the multi-tubular reactor, washed directly with water and alkali, dried with a molecular sieve, condensed, collected by rectification, and then samples were taken and analyzed. After an hour, 27.85 Kg trifluorochloroethylene having a purity of 99.91% was obtained. The conversion ratio of 1,1,2-trifluo-1,2,2-trichloroethane was 99.1%, and the yield was 99.06%.
The Examples as set forth above should not be construed as limiting the present invention in any way. It should be understood that any technical solutions obtained by equivalent substitutions or variations would fall within the scope of the present invention. | A process for preparing trifluorochloroethylene including: in a multi-tubular reactor, hydrogenation reacting 1,1,2-trifluoro-1,2,2-trichloroethane directly with a catalyst potassium zinc trihydride to obtain trifluorochloroethylene, wherein the catalytic reaction is performed at a temperature of 250-350° C. and a pressure of 0.7-1.0 MPa for 10-20 seconds. The conventional process in which zinc powder is used for dechlorination or hydrogen is used for dechlorination through hydrogenation with the action of a noble metal catalyst is avoided in the process disclosed herein. The present process substantially reduces the production cost of trifluorochloroethylene, and substantially increases the product yield, which can be up to 99% or more. | 2 |
CO-PENDING PATENT APPLICATIONS
This Nonprovisional Patent Application is a Continuation Application to Nonprovisional patent application Ser. No. 13/360,805, filed on Jan. 30, 2012 by inventor Robert Mykland and titled “SYSTEM AND METHOD FOR COMPILING MACHINE-EXECUTABLE CODE GENERATED FROM A SEQUENTIALLY ORDERED PLURALITY OF PROCESSOR INSTRUCTIONS”.
Nonprovisional patent application Ser. No. 13/360,805 is hereby incorporated by reference in its entirety and for all purposes, to include claiming benefit of the priority date of filing of Nonprovisional patent application Ser. No. 13/360,805.
This Nonprovisional Patent Application is also a Continuation-in-Part Application to Nonprovisional patent application Ser. No. 13/301,763, filed on Nov. 21, 2011 by inventor Robert Mykland and titled “CONFIGURABLE CIRCUIT ARRAY”.
Nonprovisional patent application Ser. No. 13/301,763 is hereby incorporated by reference in its entirety and for all purposes, to include claiming benefit of the priority date of filing of Nonprovisional patent application Ser. No. 13/301,763.
In addition, this Nonprovisional Patent Application is a Continuation-in-Part Application to Provisional Patent Application Ser. No. 61/500,619, filed on Jun. 24, 2011 by inventor Robert Mykland. Provisional Patent Application Ser. No. 61/500,619 is hereby incorporated by reference in its entirety and for all purposes, to include claiming benefit of the priority date of filing of Provisional Patent Application Ser. No. 61/500,619.
FIELD OF THE INVENTION
The present invention relates to information technology. More particularly, the present invention relates to methods of and systems for modifying software code for application with programmable logic.
BACKGROUND OF THE INVENTION
The prior art provides software programs that consist of sequences of machine-executable commands wherein overlapping logic branches are sometimes included. The application of prior art software programs exhibiting overlapping branches in programming reconfigurable logic can inhibit or degrade the performance of the reconfigurable logic. Certain reconfigurable logic simply cannot reliably execute software programs that present one or more overlapping branches.
There is therefore a long-felt need to provide methods and systems that enable a conversion of an originating software program having one or more overlapping branches into a resultant software program that includes either no overlapping branches or fewer overlapping branches than the originating software program.
SUMMARY AND OBJECTS OF INVENTION
It is an object of the invented method to provide a method and a system that enable the conversion of an originating software program having one or more overlapping logic branches into a resultant software program that includes either no overlapping branches, or fewer overlapping branches than the originating software program.
It is another optional object of the present invention to provide a system and method for modifying a plurality of sequential software instructions to generate a resultant software program that may be executed by a computer, an applications specific circuit and/or a custom device logic circuit having programmable logic circuitry, reconfigurable logic circuitry, and/or an array of reconfigurable logic circuits.
It is yet another optional object of the invented method to provide a system and method wherein the resultant software program may be provided to and executed by a computer and/or a data processing system that comprises a reconfigurable logic processor.
Towards these objects and other objects that will be made obvious in light of this disclosure, a first version of the invented method provides a method and a system that modifies a plurality of software encoded instructions to generate a resultant software program that may be executed by and/or in concert with reconfigurable logic circuitry.
According to the method of the present invention (hereinafter “the invented method”), a source software program is provided that comprises a sequentially ordered series of machine-executable instructions. The source software program, or “source program” is then modified by finding one, more than one, or each instance of overlapping conditional logic branch pairs and generating a resultant code that provides equivalent logical flow of the source program but eliminates or reduces the instances of overlapping conditional branching of the source program.
According to a first optional aspect of the invented method, the source program is modified by (a.) locating an instance of instructions (hereinafter “back overlap pattern”) of the source program that instantiate a pair of overlapping conditional back branches when these instructions of an instant back overlap pattern are executed in a descending order from a first-executed instruction to a last-executed instruction of the source program; (b.) deriving a set of instructions (hereinafter “back set”) that when executed are logically equivalent to the back overlap pattern, wherein the back set do not encode overlapping conditional back branches; and (c.) replacing the back overlap pattern with the back set.
The first optional aspect of the invented method may be applied to either the entire source program or a selected instruction sequence of the source program (hereinafter “selected sequence”) to generate a first resultant code that when executed does not instantiate overlapping conditional back branches. The first resultant code may be derived from the selected sequence by modification of the selected sequence in an ascending order proceeding from a last-executed conditional back branch instruction of the selected sequence to a first-executed back branch target label of the selected sequence, wherein the first-executed back branch target label is located earlier in the selected sequence than the last-executed conditional back branch instruction.
In a second optional aspect of the invented method, a second resultant code may generated by modification of the first resultant code, wherein the first resultant code is modified by sequentially finding each pair of mixed overlapping conditional branches of the first resultant code, wherein each pair of mixed overlapping conditional branches includes a conditional back The second resultant code provides a process flow that is logically equivalent to both the selected sequence and the first resultant code, and wherein the second resultant code does not instantiate either mixed overlapping conditional branches or overlapping conditional back branches. The preferred order of deriving the second resultant code from the first resultant code is in an ascending order proceeding from a last-executed instruction of the first resultant code or selected sequence and toward a first-executed instruction of the first resultant code or selected sequence.
According to the second optional aspect of the invented method, an instruction pattern of the selected sequence or the first resultant code is identified as an “owner overlap pattern” when the owner overlap pattern of instructions includes a forward conditional branch instruction that is located within the first resultant code or selected sequence in between (a.) a back conditional branch instruction and (b.) a back target label of the instant back conditional branch instruction. Each toe overlap pattern thereby includes instructions that define a forward conditional branch that overlaps a back conditional branch, and each instance of owner overlap pattern is preferably replaced with an “owner set” of instructions, wherein each owner set provides the same logical process flow of a selected set of owner overlap pattern but eliminates or reduces overlapping conditional branching.
According further to the second optional aspect of the invented method, an instruction pattern of the selected sequence or the first resultant code is identified as a “toe overlap pattern” when the toe overlap pattern of instruction includes a forward conditional branch instruction (a.) is located earlier in the selected sequence or the first resultant code, i.e., more proximate to the first-executed instruction of the selected sequence or first resultant code, than a back target label of a back conditional branch instruction and (b.) the instant forward conditional branch instruction points to a forward target label that is positioned between the instant back target label and the back conditional branch instruction that points to the instant back target label. Additionally according to the second optional aspect of the invented method, each toe overlap pattern includes instructions that define a forward conditional branch that overlaps a back conditional branch, and each toe overlap pattern of instructions is preferably replaced with a “toe set” of instructions, wherein each toe set provides the same logical process flow of the originating toe overlap pattern of instructions but eliminates or reduces overlapping conditional branching.
According to a third optional aspect of the invented method, the second resultant code is modified to generate a third resultant code by (a.) locating a yet alternate instance of instructions (hereinafter “forward overlap pattern”) of the second resultant code that instantiate a pair of overlapping conditional front branches when these forward overlap instructions are executed; (b.) deriving a set of instructions (hereinafter “forward set”) that when executed are logically equivalent to the forward overlap pattern, wherein the forward set do not encode overlapping conditional forward branches; and (c.) replacing the forward overlap pattern with the forward set in a third resultant code.
The preferred order of deriving the third resultant code from the second resultant code is in a descending order proceeding from a first-executed instruction of the second resultant code and toward a last-executed instruction of the second resultant code.
In a fourth optional aspect of the invented method, one or more elements of one or more aspects of the invented method are applied in singularity or combination to modify the source program or an instruction sequence thereof of overlapping conditional branches by generating a logically equivalent resultant code. For example, a fourth resultant code might be generated by applying the third aspect of the invented code to the source program and to thereby replace all forward overlap instructions of the source program with forward sets and remove some or all forward overlapping conditional branches from the fourth resultant code. In another example, a fifth resultant code might be generated by applying the second aspect of the invented code to the source program and to thereby replace all mixed overlap instructions of the source program with owner sets and/or toe sets and thereby remove some or all mixed overlapping conditional branches from the fifth resultant code.
In a yet another optional aspect of the invented method, one, more than one, or all of the first through the third aspects of the invented method may be in singularity, in combination and/or sequentially applied to the selected sequence or the source program to derive a fifth resultant software program, wherein the resultant software may be executed by a computational system having programmable logic, reconfigurable logic and/or an information technology network that comprises reconfigurable or programmable logic.
In still another optional aspect of the method the present invention, an order of modifying a source program to remove overlapping branches is implemented in the following order: (1.) firstly, all overlapping back branch pairs are sequentially removed in an ascending order within the source program, wherein new code sequences are generated within a resultant software program that provide logic equivalent to the logic of the removed overlapping back branches; (2.) secondly, all pairs of overlapping back and forward branches are sequentially removed in an ascending order within the source program, wherein new code sequences are generated that provide logic equivalent to the logic of the removed overlapping pairs of back and forward branches; and (3.) thirdly, all overlapping forward branch pairs are sequentially removed in a descending order within the source program, wherein new code sequences are generated that provide logic equivalent to the logic of the removed overlapping forward branches.
In an additional optional aspect of the invented method, a computational system having reconfigurable logic, and/or an information technology network that comprises reconfigurable logic, is provided that accepts and executes the resultant software code derived in accordance with one or more of the recited aspects of the invented method.
In certain still alternate preferred embodiments of the invented method, some or all of an array of reconfigurable logic circuits are communicatively or bi-directionally communicatively coupled to a memory, a back buffer, and one or more memory controllers.
Additionally or alternately, the invented method provides a reprogrammable logic unit as disclosed in U.S. Pat. No. 7,840,777 issued on Nov. 23, 2010 to inventor Robert Mykland and titled “Method and apparatus for directing a computational array to execute a plurality of successive computational array instructions at runtime” and a method of programming thereof.
Still additionally or alternately, the invented method provides a reprogrammable logic unit as disclosed in U.S. Nonprovisional patent application Ser. No. 13/301,763 filed on Nov. 21, 2011 to inventor Robert Mykland and titled “CONFIGURABLE CIRCUIT ARRAY” and a method of programming thereof.
INCORPORATION BY REFERENCE
All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference in their entirety and for all purposes to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
Such incorporations include U.S. Pat. No. 8,078,849 (inventors: Libby, et al.; issued on Dec. 13, 2011) titled “Fast execution of branch instruction with multiple conditional expressions using programmable branch offset table”; U.S. Pat. No. 7,840,950 (titled Stoodley, et al.; issued on Nov. 23, 2010) titled “Programmatic compiler optimization of glacial constants”; U.S. Pat. No. 7,840,777 (inventor: Mykland; issued on Nov. 23, 2010) titled “Method and apparatus for directing a computational array to execute a plurality of successive computational array instructions at runtime”; U.S. Pat. No. 6,438,737 (inventors: Morelli, et al.; issued on Aug. 20, 2002) titled “Reconfigurable logic for a computer”; U.S. Pat. No. 7,171,659 (inventors: Becker, et al.; issued on Jan. 30, 2007) titled “System and method for configurable software provisioning”; U.S. Pat. No. 7,167,976 (inventor: Poznanovic, D.; issued on Jan. 23, 2007) titled “Interface for integrating reconfigurable processors into a general purpose computing system”; U.S. Pat. No. 7,155,602 (inventor: Poznanovic, D.; issued on Dec. 26, 2006) titled “Interface for integrating reconfigurable processors into a general purpose computing system”; U.S. Pat. No. 7,076,575 (inventor: Baitinger, et al.; issued on Jul. 11, 2006) titled “Method and system for efficient access to remote I/O functions in embedded control environments”; U.S. Pat. No. 6,868,017 (inventor: Ikeda, K.; issued on Mar. 15, 2005) titled “Integrated circuit device”; and U.S. Pat. No. 6,717,436 (inventors: Kress, et al.; issued on Apr. 6, 2004) titled “Reconfigurable gate array”.
Such incorporations further include in U.S. Nonprovisional patent application Ser. No. 13/301,763 filed on Nov. 21, 2011 to inventor Robert Mykland and titled “CONFIGURABLE CIRCUIT ARRAY”; US Patent Appn. Publication Ser. No. 20060004997 (inventor: Mykland, Robert; published on Jan. 5, 2006) titled “Method and apparatus for computing”; US Patent Appn. Publication Ser. No. 20040068329 (inventor: Mykland, Robert; published on Apr. 8, 2004) titled “Method and apparatus for general purpose computing”; US Patent Appn. Publication Ser. No. 20040019765 (inventor: Klein, Robert C. JR.; published on Jan. 29, 2004) titled “Pipelined reconfigurable dynamic instruction set processor”; and US Patent Appn. Publication Ser. No. 20040107331 (inventor: Baxter, Michael A.; published on Jun. 3, 2004) titled “Meta-address architecture for parallel, dynamically reconfigurable computing”.
In addition, each and all publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent in their entirety and for all purposes as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. The publications discussed or mentioned herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Furthermore, the dates of publication provided herein may differ from the actual publication dates which may need to be independently confirmed.
BRIEF DESCRIPTION OF THE FIGURES
These, and further features of the invention, may be better understood with reference to the accompanying specification and drawings depicting the preferred embodiment, in which:
FIG. 1 is a functional block diagram of a prior art computational device having a processor module communicatively coupled with a memory module, a network interface, one or more input modules and one or more output modules;
FIG. 2 is a functional block diagram of a reconfigurable computational device having a reconfigurable logic circuit array communicatively coupled with a memory controller, a system memory, a back buffer, one or more input modules, one or more output modules, and an optional processor;
FIG. 3 is an information technology network that comprises at least one prior art computational device of FIG. 1 and optionally one or more reconfigurable computational devices of FIG. 2 ;
FIG. 4 is a representation of a sequential listing of software-encoded, machine-executable instructions that comprise or are provided within a selected sequence of a source software program or a resultant program as disclosed within;
FIG. 5 presents a detail view of the sequential listing of FIG. 4 that includes an exemplary back overlap pattern that defines two overlapping conditional back branches;
FIG. 6A is a flow chart of an application of the first aspect of the invented method wherein overlapping back branches are sequentially removed in an ascending order within the selected sequence of instructions of FIG. 4 and FIG. 5 , and each back overlap pattern of is replaced with a back set generated therefrom;
FIG. 6B is a flow chart of a derivation of an exemplary back set from the exemplary back overlap pattern of FIG. 6A and an imposition of the exemplary back set into the selected sequence of FIG. 4 in the application of the method of FIG. 6A ;
FIG. 6C is a representation of a detail of a first resultant software code that includes a back set of instructions derived from the exemplary back overlap pattern of FIG. 5 and in accordance with the first aspect of the invented method of FIGS. 6A and 6B ;
FIG. 7 presents a detail view of a second portion of the selected sequence of instructions of FIG. 4 that an owner pattern of overlapping conditional branches and a toe pattern of overlapping conditional branches;
FIG. 8 is a flow chart of an application of the second aspect of the invented method wherein overlapping owner patterns and toe patterns an are sequentially removed in an ascending order within the first resultant code of FIGS. 1 and 2 , and each overlapping owner pattern and toe pattern is respectively is respectively replaced with an equivalent owner set or toe set;
FIG. 9A is a detail view of an exemplary owner pattern of the first resultant code and/or the source program of FIGS. 1 and 2 ;
FIG. 9B is a flow chart of a derivation and imposition of an owner set into the software code of FIG. 9A ;
FIG. 9C is a representation of the owner set generated by the method of FIG. 9B as written into the second resultant software of FIGS. 1 and 2 ;
FIG. 10A is a detail view of an exemplary toe pattern of the first resultant code and/or the source program of FIGS. 1 and 2 ;
FIG. 10B is a flow chart of a derivation and imposition of a toe set into the software code of FIG. 10A ;
FIG. 10C is a representation of the toe set generated by the method of FIG. 9B as written into the second resultant software of FIGS. 1 and 2 ;
FIG. 11 presents a detail view of the sequential listing of FIG. 4 , the first resultant code of FIGS. 1 and 2 and/or the second resultant code of FIGS. 1 and 2 that includes an exemplary forward overlap pattern that defines two overlapping conditional forward branches;
FIG. 12A is a flow chart of an application of the third aspect of the invented method wherein overlapping forward branches are sequentially removed in a descending order within the source program, the first resultant code and/or the second resultant code of FIGS. 1 and 2 , and whereby each forward overlap pattern is replaced with a forward set derived therefrom;
FIG. 12B is a flow chart of a derivation and imposition of an exemplary forward set into the software code of FIG. 11 in the application of the method of FIG. 12A ;
FIG. 12C is a representation of a detail of a third resultant software code that includes a back set of instructions derived from the exemplary back overlap pattern of FIG. 12A and in accordance with the second aspect of the invented method of FIGS. 12A and 12B ;
FIG. 13 is a flow chart of a successive application of the first four aspects of the invented method of FIGS. 5 through 1C to a sequential listing of software encoded instructions of FIG. 4 ; and
FIG. 14 is a process chart of a derivation of resultant software code of FIG. 13 and application of the resultant software code by a computational system having reconfigurable logic of FIG. 2 and/or an informational technology network of FIG. 3 comprising reconfigurable logic. In step 14 . 2 the source program is input into either the computer 2 , the reconfigurable computer 4 , and/or distributed within the system 2 , 3 C & 4 of the network 3 .
DETAILED DESCRIPTION
It is to be understood that this invention is not limited to particular aspects of the present invention described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Methods recited herein may be carried out in any order of the recited events which is logically possible, as well as the recited order of events.
Where a range of values is provided herein, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits ranges excluding either or both of those included limits are also included in the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the methods and materials are now described.
It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.
FIG. 1 is a functional block diagram of a prior art computational device 2 (hereinafter “computer” 2 ) having a processor module 2 A communicatively coupled with a memory module 2 B, a network interface 2 C, one or more input modules 2 D. 1 - 2 D.N and one or more output modules 2 E. 1 - 2 E.N. The processor module 2 A may comprise one or more digital electronic microprocessors, such as, but not limited to, a COR I7 Extreme Processor™ processor or a NEHALEM™ processor as marketed by Intel Corporation of Santa, or other suitable electronic logic processors known in the art.
The computer 2 may be (a.) a network-communications enabled SUN SPARCSERVER™ computer workstation marketed by Sun Microsystems of Santa Clara, Calif. running LINUX™ or UNIX™ operating system; (b.) a network-communications enabled personal computer configured for running WINDOWS XP™, VISTA™ or WINDOWS 7™ operating system marketed by Microsoft Corporation of Redmond, Wash.; (c.) a VAIO FS8900™ notebook computer marketed by Sony Corporation of America, of New York City, New York; (d.) a PowerBook G4™ personal computer as marketed by Apple, Inc. of Cupertino, Calif.; (e.) an IPAD™ tablet computer as marketed by Apple, Inc. of Cupertino, Calif.; (f.) an IPHONE™ cellular telephone as marketed by Apple, Inc. of Cupertino, Calif.; or (g.) an other suitable computational device known in the art.
A bi-directional internal communications bus 2 F communicatively couples and provides electrical power to the processor module 2 A with the memory module 2 B, the network interface 2 C, the input modules 2 D. 1 - 2 D.N and the output modules 2 E. 1 - 2 E.N.
One or more input modules 2 D. 1 - 2 D.N may be or comprise a computer keyboard, a computer mouse, a point and click selection device, a track ball, a mouse pad, an external disk drive module, a memory stick and/or other suitable user input or data input devices known in the art. One or more output modules 2 E. 1 - 2 E.N may be or comprise a display device having a display screen, a touch screen, a portable memory module and and/or other suitable data output devices known in the art.
The network interface 2 C is adapted to bi-directionally communicatively couple the computer 2 with an electronic communications network 3 , such as the Internet, a computer network and/or a telephony network. It is understood that the network interface 2 C may be adapted to provide wireless bi-directional communication between the computer 2 and the electronic communications network 3 .
The system memory 2 B stores an operating system SW. 1 , a first system software SW. 2 , an originating software program SW. 3 , and a plurality of resultant software programs R. 1 -R.N. The operating system SW. 1 directs the operations of computer 2 , controlling and scheduling the execution of other programs, and managing storage, input/output actions, and communication resources, and may be or comprise a LINUX™ or UNIX™ or derivative operating system, such as the DEBIAN™ operating system software as provided by Software in the Public Interest, Inc. of Indianapolis, Ind.; a WINDOWS XP™, VISTA™ or WINDOWS 7™ operating system as marketed by Microsoft Corporation of Redmond, Wash.; a MAC OS X operating system or iPhone G4 OS™ operating system as marketed by Apple, Inc. of Cupertino, Calif.; or an other suitable operating system known in the art.
The first system software SW. 2 provides machine executable instructions to cause and enable the computer 2 to instantiate the aspects of the invented method as disclosed herein. The originating source software program SW. 3 (hereinafter “source program” SW. 3 ) is a sequential series of instructions 4000 - 4999 SEQ upon which one or more aspects of the invented method may be applied by the computer 2 to generate each of the plurality of resultant software programs R. 1 -R.N (hereinafter “resultant code” R. 1 -R.N. It is understood that the term “source program” as used within the present disclosure indicates machine-executable software code and does not refer to higher-level source code programs or source programming languages. It is further understood that each resultant code R. 1 -R.N may be generated by the computer 2 applying on or more aspects of the invented method to the source program SW. 3 alternately in singularity and in various combinations and sequences to generate different resultant code R. 1 -R.N.
FIG. 2 is a functional block diagram of a reconfigurable computational device 4 (hereinafter “reconfigurable computer” 4 ) having a reconfigurable logic circuit array (hereinafter “RLC” 4 A) communicatively coupled with a memory controller 4 B (hereinafter “MC” 4 B), a system memory 4 C, a back buffer 4 D, one or more input modules 2 D. 1 - 2 D.N, the network interface 2 C, one or more output modules 2 E. 1 - 2 E.N, and an optional processor module 2 A. The bi-directional internal power and communications bus 2 F couples and provides electrical power to the RLC 4 A, the MC 4 B, the system memory 4 C, the back buffer 4 D, the optional processor module 2 A, the network interface 2 C, the input modules 2 D. 1 - 2 D.N and the output modules 2 E. 1 - 2 E.N.
The RLC 4 A is further directly bi-directionally communicatively coupled with the system memory 4 C. The back buffer 4 D is bi-directionally communicatively coupled with the system memory 4 C and the MC 4 B. The back buffer 4 D is further adapted to program the RLC 4 A. The MC 4 B is bi-directionally communicatively coupled with the system memory 4 C and the back buffer 4 D. The MC 4 B is further adapted to program the RLC 4 A.
The network interface 2 C is adapted to bi-directionally communicatively couple the reconfigurable computer 4 with an electronic communications network 3 , such as the Internet, a computer network and/or a telephony network. It is understood that the network interface 2 C may be adapted to provide wireless bi-directional communication between the reconfigurable computer 4 and the electronic communications network 3 .
A second operating system SW. 4 directs the operations of reconfigurable computer 4 , controlling and scheduling the execution of other programs, and managing storage, input/output actions, and communication resources, and may be or comprise the system software SW. 1 and/or some or all aspects of the software encoded instructions for directing the RLC 4 A to execute a plurality of successive computational array instructions at runtime as disclosed in Nonprovisional patent application Ser. No. 13/301,763, filed on Nov. 21, 2011 by inventor Robert Mykland and titled “CONFIGURABLE CIRCUIT ARRAY”.
The second system software SW. 5 provides machine executable instructions to cause and enable the reconfigurable computer 4 to instantiate the aspects of the invented method as disclosed herein. It is further understood that each resultant code R. 1 -R.N may be generated by applying on or more aspects of the invented method by the reconfigurable computer 4 to the source program SW. 3 in various combinations and sequences to generate different resultant code R. 1 -R.N.
FIG. 3 is a schematic diagram of the electronics communications network 3 (hereinafter “network” 3 ) that comprises at least one computer 2 and/or at least one reconfigurable computer 4 . The network 3 is an information technology network that may additionally comprise a telephony network 3 A and/or the Internet 3 B. The network 3 may further comprise a database server 3 C, wherein the database server 3 C may include one or more elements 2 A- 4 D or aspects of the computer 2 and/or the reconfigurable computer 4 .
It is understood that one or more of the aspects of the invented method may be executed in singularity, in concert, or in combination by one or more computer 2 , reconfigurable computer 4 and/or database server 3 C.
It is further understood that more computer 2 , reconfigurable computer 4 and/or database server 3 C may be applied to derive one or more resultant code R. 1 -R.N by the application of various aspects of the invented method from the source program SW. 3 or another resultant code R. 1 -R.N.
FIG. 4 is a representation of a representative sequential listing of software-encoded, machine-executable instructions 4000 - 4999 SEQ that comprise, or are provided within, the source program SW. 3 and/or a resultant code R. 1 -R.N. The executable instructions 4000 - 4999 SEQ are ordered for an intended order of sequential execution of the source program SW. 3 or resultant code R. 1 -R.N starting at a first instruction 4000 and proceeding through the execution of intervening instructions 4001 through 4998 until the execution of a last instruction 4999 , wherein branch operations can cause the processor module 2 A or the RLC 4 A to not execute certain instructions 4000 - 4999 SEQ and/or to repeatedly execute certain instructions 4000 - 4999 SEQ.
It is understood that the term “descending order” is defined herein to denote executing, instantiating, analyzing, processing or examining the instructions 4000 - 4999 SEQ in sequential order starting at the first instruction 4000 and proceeding to the last instruction 4999 .
It is also understood that the term “ascending order” is defined herein to denote executing, instantiating, analyzing, processing or examining the instructions 4000 - 4999 SEQ in sequential order opposite form the intended order of execution starting at the last instruction 4999 and proceeding to the first instruction 4000 .
It is further understood that exemplary first forward branch XFB. 1 and exemplary first back branch XBB. 1 can be applied by the computer 2 to direct the processor module 2 A to alternately (a.) skip over and not execute certain instructions; or (b.) to repeat an execution of certain instructions. For example, a first exemplary forward branch conditional logical query XFBI 1 of the instruction 4100 directs the processor module 2 A to proceed from executing step 4100 to step 4199 when a logical condition or value of X 1 is determined to exist at the instant execution of step 4100 . Logical instructions 4101 to 4199 are thus not executed by the computer 2 when the processor module 2 A finds in an execution of instruction 4100 that a logical condition X 1 exists, but rather the computer 2 proceeds to execute instruction 4199 , i.e., forward target label 4199 , as a next executed instruction after the instant execution of step 4100 .
The term “forward branch instruction” is defined herein to denote a software encoded conditional logical query or test wherein a determination by the executing computer 2 or 4 of a condition or value directs the computer 2 or the reconfigurable computer 4 to proceed from the instant instruction to a forward target label, e.g., instruction 4199 , without executing all instructions of comprising the source program SW. 3 or resultant code R. 1 -R.N intervening between the instant exemplary forward branch instruction XFBI 1 and an associated exemplary forward target label XFT 1 .
It is further understood that a back branch conditional logical query or test of the first exemplary back branch instruction XBBI 1 located within instruction 4399 directs the processor module 2 A to proceed from executing back branch instruction 4399 to executing an instruction 4300 associated with an exemplary back target label XBT 1 when the processor module 2 A finds in an execution of instruction 4399 that a pre-specified logical condition exists. According to the exemplary first back branch instruction XBBI 1 , the processor module 2 A proceeds from instruction 4399 to execute instruction 4300 when a logical condition Y 1 is met in the execution of instruction 4399 that is associated with the first back branch instruction XBBI 1 .
The term “back branch instruction” is defined herein to denote a software encoded conditional logical query or test wherein a determination of a condition or value directs the computer 2 or the reconfigurable computer 4 to proceed from processing the instant back branch instruction, e.g., instruction 4399 , to next executing a back target label XBT 1 , e.g., the back target label XBT 1 associated with instruction 4300 .
It is still further understood that one or more conditional logical queries or tests X 1 -XN or Y 1 -YN may be a negative query or test, wherein a determination of a nonexistence of a specified logical condition or value at the time of execution of the instant branch instruction FB. 1 -FB.N or BB. 1 -BB.N will lead to a positive finding of the query or test and thereby result in an activation of an associated back branch BB. 1 -BB.N or a forward branch FB. 1 -FB.N.
The term “back branch instruction” is defined herein to denote a conditional logical query or test wherein a positive finding directs the computer 2 or the reconfigurable computer 4 to proceed from an instant back branch instruction, e.g., instruction 4399 , to a back target label, e.g., instruction 4300 , wherein the back target label is located previous to the instant back branch instruction in the instruction sequence of instructions 4000 - 4999 SEQ.
It is understood that the terms “target” and “target label” as used herein indicate software code 4199 & 4300 within the instruction sequence 4000 - 4999 SEQ to which a computer 2 or 4 next references or executes after the execution of a branch instruction 4100 & 4399 as determined by the host computer 2 or 4 .
FIG. 5 presents a detail view of a first portion of the sequential listing of instructions 4000 - 4999 SEQ that includes a back overlapping pattern that defines two overlapping back branches BB. 1 & BB. 2 . A sequence A of instructions of the source program SW. 3 is disposed between a second back target label BT 2 and a first back target label BT 1 .
A sequence B of instructions of the source program SW. 3 is disposed between the first back target label BT 1 and a second back branch instruction BBI 2 . A sequence C of instructions of the source program SW. 3 is disposed between the second branch instruction BBI 2 and a first back branch instruction BBI 1 . The three sequence of instructions A, B & C of FIG. 5 are placed in a descending order from Sequence A to Sequence C within the source program instructions 4000 - 4999 SEQ.
According to the logic of the first back branch BB. 1 , a program execution of the source program SW. 3 by the processor module 2 A proceeds from the first back branch instruction BBI 1 to the first back target label BT 1 when a logic condition of X 1 is met In the execution of the first back branch instruction BBI 1 .
In addition, according to the logic of the second back branch BB. 2 a program execution of the source program SW. 3 by the processor module 2 A proceeds from the second back branch instruction BBI 2 to the second back target label BT 2 when a logic condition of Y 1 is met in the execution of the second back branch instruction BBI 2 .
FIG. 6A is a flow chart of a portion of the instruction sequence 4000 - 4999 SEQ that in the generation of a first resultant code R. 1 replaces the back overlap pattern of FIG. 5 with a back set of FIG. 6C and thereby remove the overlapping back branches from the sequence of instructions 4000 - 4999 SEQ from the first resultant code R. 1 . A current line value CRNT and a first line value FIRST are initialized in step 6 A. 02 wherein the current line value CRNT is equal to the value of the final line of code 4999 of the sequence of instructions 4000 - 4999 SEQ and the first line value FIRST is set equal to the first line of code 4000 of the sequence of instructions 4000 - 4999 SEQ. In step 6 A. 04 the computer 2 determines if the current line value CRNT has been decremented by cycling through the loop of steps 6 A. 10 through 6 A. 22 to be made equal to or less than the first line value FIRST of 4000 . When the computer 2 determines in step 6 A. 04 that the current line value CRNT has been decremented to be equal to or lesser than the first line value FIRST, the computer 2 proceeds on to store the software code modified by execution of steps 6 A. 04 through 6 A. 22 as a first resultant code R. 1 , and proceeds from step 6 A. 06 to step 6 A. 08 and to perform alternate computational operations.
When the computer 2 determines in step 6 A. 04 that the code line value CRNT of the sequence of instructions 4000 - 4999 SEQ is greater than the first line value FIRST, the computer 2 proceeds on to step 6 A. 10 to determine if software code at line value CRNT provides a back branch instruction. When the computer 2 determines in step 6 A. 10 that the software code at line value CRNT is not a back branch instruction, the computer 2 proceeds onto step 6 A. 12 and to decrement the current line value CRNT. The computer 2 proceeds from step 6 A. 12 to an additional execution of step 6 A. 04 . When the computer 2 determines in step 6 A. 10 that the software code at line value CRNT is a back branch instruction BBI 1 , the computer 2 proceeds onto step 6 A. 14 and to seek a first instance of an overlapping additional back branch instruction BBI 2 , or “OBB”, positioned between a first back branch instruction BBI 1 determined in the last instance of step 6 A. 10 and a first back target label BT 1 as specified by the first back branch instruction BB 1 . When an overlapping second back branch instruction BB 2 is not found by the computer 2 within the sequence of instructions SEQ between the first branch instruction BB 1 and the first back target label BT 1 in step 6 A. 16 , the computer 2 proceeds onto step 6 A. 18 and to load a value of the code line associated with the first back target label BT 1 and therefrom onto step 6 A. 04 .
When an overlapping second back branch instruction BB 2 is discovered by the computer 2 within the sequence of instructions SEQ between the first branch instruction BB 1 and the first back target label BT 1 in step 6 A. 16 , the computer 2 proceeds onto step 6 A. 20 and to apply a back branch algorithm of the first aspect of the method of the present invention as disclosed in FIG. 6B and accompanying text. The computer 2 proceeds from step 6 A. 20 to step 6 A. 22 in the process of generating the first resultant code R. 1 and to update all pointers and references within the source program SW. 3 that have been altered by the modifications of the instruction sequence 4000 - 4999 SEQ in the most recent instance of step 6 A. 20 .
FIG. 6B is a flow chart of an exemplary instance of step 6 A. 20 of an instantiation of the back branch algorithm of the first aspect of the invented method, wherein a pair of overlapping back branches BB. 1 &BB. 2 are replaced with a back set that comprises logically equivalent resultant code, wherein the equivalent first resultant code R. 1 includes a first resultant first forward branch R.FB. 1 and a first resultant back branch R.BB. 1 and the second back branch is removed from resultant code. In step 6 B. 02 a new first resultant forward target label R.FT 1 is inserted in the instruction sequence 4000 - 4999 SEQ immediately after the first back branch instruction BBI 1 . In step 6 B. 04 the second back branch instruction BBI 2 is overwritten with a new first resultant forward branch instruction R.FBI 1 , wherein the new first resultant forward branch instruction R.FBI 1 specifies that when a logical condition of Y 1 is met that execution of the resultant code R. 1 by the computer 2 or the reconfigurable computer 4 proceeds from first resultant forward branch instruction R.FBI 1 to the first resultant forward target label R.FT 1 of the first resultant code R. 1 . In step 6 B. 06 a new first resultant back branch instruction R.BBI 1 is inserted into the resultant code R. 1 , wherein the new first resultant back branch instruction R.BBI 1 specifies that when the logical condition of Y 1 is met that execution of the resultant code R. 1 by the computer 2 or the reconfigurable computer 4 proceeds from first resultant back branch instruction R.BBI 1 to the original second back target label BT 2 . The current value CRNT is incremented by a value of two in step 6 B. 08 in recognition that the length of the resultant code of FIG. 6C contains two more instructions than the original code of FIG. 6A .
FIG. 6C is an illustration of an element of a back set of a first resultant code R. 1 that is derived from the first code portion of FIG. 5 in accordance with the first aspect of the invented method and in an implementation of the method of FIG. 6B , wherein the system software SW. 2 or SW. 5 modifies the source program SW. 3 to generate the first resultant code R. 1 by reformulating the second back branch BB. 2 as a first resultant forward branch R.FB. 1 and a first resultant back branch R.BB. 1 .
According to the first resultant forward branch R.FB. 1 , a program execution of the resultant code R. 1 by the processor module 2 A or RLC 4 A proceeds from a resultant forward branch instruction R.FB 1 of the first resultant forward branch R.FB. 1 to the second branch target label BT 2 when a logic condition of Y 1 is met in the execution of the resultant forward branch instruction R.FBI 1 .
According to the first resultant back branch R.BB. 1 a program execution of the resultant code R. 1 by the processor module 2 A or RLC 4 A proceeds from a resultant third back branch instruction R.BBI 3 to a resultant back target label R.BT 3 when a logic condition of Y 1 is met in the execution of the resultant third back branch instruction R.BBI 3 .
The first resultant code R. 1 is organized as follows: (1.) sequence A of the source program SW. 3 is disposed between the resultant branch third target label R.BT 3 and the first branch target label BT 1 ; (2.) sequence B of the source program SW. 3 is disposed between the first branch target label BT 1 and the resultant first forward branch instruction R.FBI 1 ; (3.) sequence C of the source program SW. 3 is disposed between the resultant first forward branch instruction R.FBI 1 and the back branch instruction BBI 1 ; (4.) and the resultant first branch target label R.FT 1 is disposed between the back branch instruction BBI 1 and the third resultant back branch instruction R.BB 3 .
FIG. 7 presents a detail view of the instruction sequence 4000 - 4999 SEQ that includes the first back branch BB. 1 and two exemplary overlapping forward branches OFB. 1 & OFB. 2 . The second optional aspect of the invented method is applied to provide a second resultant code R. 2 that removes forward branch overlapping of each back branch of the first resultant code R. 1 in that generation of a second resultant code R. 2 , wherein the second resultant code R. 2 includes an equivalent logical flow of the instruction sequence 4000 - 4999 SEQ of the instruction sequence 4000 - 4999 .
For the purpose of explanation of the second aspect of the invented method, FIG. 7 presents an exemplary toe overlapping forward branch TFB. 1 and an exemplary owner overlapping forward branch OFB. 1 .
The exemplary first toe overlapping forward branch TOFB. 1 is generated by a toe forward branch instruction TFBI that both (a.) is positioned earlier in the instruction sequence 4000 - 4999 SEQ than the target label BT 1 of the first back branch instruction BBI 1 ; and (b.) points to a toe forward branch target TFT that is positioned between the first back branch instruction BBI 1 and the first back branch target BT 1 .
The exemplary owner overlapping forward branch OFB. 1 is generated by an owner forward branch instruction OFBI that (a.) is positioned in the instruction sequence 4000 - 4999 SEQ between the first target label BT 1 and the first back branch instruction BBI 1 ; and (b.) is directed to an owner forward target label OFT that is positioned within the instruction sequence 4000 - 4999 SEQ after the first back branch instruction BBI 1 .
FIG. 8 is a flow chart of a second portion of the first system software SW. 2 that implements the second optional aspect of the invented method and removes mutual overlapping of back branches and forward branches from the sequence of instructions 4000 - 4999 SEQ.
The current line value CRNT and the first line value FIRST are initialized in step 802 wherein the current line value CRNT is set to be equal to the value of the final line of code 4999 of the sequence of instructions 4000 - 4999 SEQ and the first line value FIRST is set to be equal to the first line of code 4000 of the sequence of instructions 4000 - 4999 SEQ. In step 804 the computer 2 determines if the current line value CRNT has been decremented by cycling through the loop of steps 810 through 816 to be made equal to or less than the first line value FIRST of 4000 . When the computer 2 determines in step 804 that the current line value CRNT has been decremented to be equal to or lesser than the first line value FIRST, the computer 2 proceeds on to store the software code modified by execution of steps 810 through 816 as the second resultant code R. 2 , and proceeds from step 806 to step 808 and to perform alternate computational operations.
When the computer 2 determines in step 804 that the code line value CRNT of the sequence of instructions 4000 - 4999 SEQ is greater than the first line value FIRST, the computer 2 proceeds on to 810 to determine if software code at line value CRNT provides a back branch instruction. When the computer 2 determines in step 810 that the software code at line value CRNT is not a back branch instruction, the computer 2 proceeds onto step 812 and to decrement the current line value CRNT. The computer 2 proceeds from step 812 to an additional execution of step 804 .
When the computer 2 determines in step 810 that the software code at line value CRNT is an exemplary third back branch instruction BBI 3 , the computer 2 proceeds onto step 814 to (a.) detect each instance on an overlapping internal forward branch instruction OFB positioned between the exemplary instant third back branch instruction BBI 3 and a third back target label BT 3 ; and (b.) apply an owner algorithm to each detected instance of forward branches that overlap the instant third branch BB. 3 to generate the second resultant code R. 2 , wherein the overlapping instructions of the first resultant code R. 1 is replaced in the second resultant code R. 2 with one or more owner sets that thereby reduce or avoid the generation of internal forward branches overlapping the instant third back branch BB. 3 .
After the removal of internal forward branches that overlap the instant exemplary third back branch BB. 3 , the computer 2 proceeds on to step 816 to remove each instance of overlapping external forward branches of the first resultant code R. 1 in the generation of the second resultant code R. 2 . In step 816 , the computer 2 proceeds to (a.) detect each instance on an overlapping external forward branch instruction OFB positioned between the exemplary instant third back target label BT 3 and the first instruction 4000 of the instruction sequence 4000 - 4999 SEQ; and (b.) apply a toe algorithm to each instance of forward branches detected in step 816 that overlap the instant third branch BB. 3 to generate the second resultant code R. 2 , wherein the overlapping instructions of the first resultant code R. 1 are replaced in the second resultant code R. 2 with one or more toe sets that thereby reduce or avoid the generation of external forward branches overlapping the instant third back branch BB. 3 .
The computer 2 proceeds from step 816 to step 812 and to decrement the current value CRNT, and therefrom to another execution of step 804 .
Referring generally to Figures and particularly to FIGS. 8, 9A, 9B, 9C, 10A, 10B and 100 , it is understood that the generation of owner sets as illustrated in FIGS. 9A, 9B and 9C may occur repeatedly in succeeding modifications of the first resultant code R. 1 , or alternatively of source code SW. 3 , in the execution of step 814 . It is understood that the generation of toe sets as illustrated in FIGS. 10A, 10B and 100 may occur repeatedly in succeeding modifications of the first resultant code R. 1 , or alternatively of source code SW. 3 , in the execution of step 816 .
FIGS. 9A through 9C illustrate the partial generation of the second resultant code R. 2 by replacement of owner instruction patterns of the first resultant code R. 1 with owner sets of the second resultant code R. 2 .
FIG. 9A presents a detail view of a first instruction sequence R 1 .SEQ 1 of the resultant code R. 1 , or optionally the source program SW. 3 , that includes an owner instruction pattern and three sequences of instructions D, E & F.
The owner instruction pattern provides a third forward branch FB. 3 that overlaps a third back branch BB. 3 , wherein the third back branch BB. 3 is formed by a third back branch instruction BBI 3 that points to a third back target label BT 3 , and the third forward branch FB. 3 is formed by a third forward branch instruction FBI 3 that points to a third forward target label FT 3 . The third forward target label FT 3 is positioned at the end of the first instruction sequence R 1 .SEQ 1 .
According to the logic of the third forward branch FB. 3 , a program execution of the first instruction sequence R 1 .SEQ 1 by the processor module 2 A proceeds from the third forward branch instruction FBI 3 to the third forward target label FT 3 when a logic condition of Y 3 is met In the execution of the third forward branch instruction FBI 3 . Furthermore, according to the logic of the third back branch BB. 3 , a program execution of the first instruction sequence R 1 .SEQ 1 by the processor module 2 A proceeds from the third back branch instruction BBI 3 to the third back target label BT 3 when a logic condition of X 3 is met In the execution of the third back branch instruction BBI 3 .
An instruction sequence D of instructions of the first resultant code R. 1 is disposed between third back target label BT 3 and the third forward branch instruction FBI 3 . An instruction sequence E of instructions of the first resultant code R. 1 is disposed between the third forward branch instruction FBI 3 and the third back branch instruction BBI 3 . An instruction sequence F of instructions of the first resultant code R. 1 is disposed between the third back branch instruction BBI 3 and the third forward target label FT 3 . The three sequences of instructions D, E & F of FIG. 9A are placed in a descending order from Sequence D to Sequence F within the instruction sequence 4000 - 4999 SEQ of the first resultant code R. 1 .
FIG. 9B is an Illustration of an execution of the owner algorithm that is applied in step 814 as often as required in ascending order within the resultant code R. 1 to replace owner overlap patterns with owner sets. Toward this end, system software SW. 2 directs the computer 2 or 4 to seek all forward branch instructions that form an owner overlap pattern in combination with the instant back branch instruction, wherein each relevant forward branch (1.) is located in the first resultant code R. 1 between the instant back branch instruction selected in the most previous execution of step 810 and the back target label of the instant back branch instruction; and (2.) forms an overlap pattern by having an associated forward target label that is located later in the first resultant code R. 1 than the instant back branch instruction.
In step 9 B. 2 a new forward target label R.FT 3 is inserted at the end of sequence E. In step 9 B. 4 , the third forward branch instruction FBI 3 is modified to point to the newly inserted forward target label R.FT 3 . In step 9 B. 6 a new owner back branch instruction R.BBI 3 is inserted into the first instruction sequence R 1 .SEQ 1 immediately after the new forward target label R.FT 3 . The owner back branch instruction R.BBI 3 includes logic that directs the computer to proceed to the third back target label BT 3 when the following logical statement is true:
[X 3 and NOT(Y 3 )].
In step 9 B. 8 a new resultant forward branch instruction R.FBI 3 is inserted into the first instruction sequence R 1 .SEQ 1 immediately after the owner back branch instruction R.BBI 3 , wherein the new resultant forward branch instruction R.FBI 3 directs execution of the second resultant code R. 2 to proceed from the forward branch instruction R.FBI 3 to the original third forward target label FT 3 of the forward branch instruction FBI 3 of the owner overlap pattern of FIG. 9A . Any and all pointers and references of the first resultant code R. 1 are updated as necessary in step 9 B. 10 in view of the addition of instructions to the first resultant code R. 1 imposed by the execution of steps 9 B. 2 - 9 B. 8 .
It is understood the that owner set of FIG. 9C creates three branches owner branches OBB. 1 , OFB. 1 & OFB. 2 in the generation of the second resultant code R. 2 , namely a first owner forward branch OFB. 1 that extends from the third forward branch instruction FBI 3 to the resultant forward target label R.FT 3 and is activated when the logical state of Y 3 is true at the moment of execution of the third forward branch instruction FBI 3 ; a first owner back branch OBB. 1 that extends from the owner back branch instruction R.BBI 3 to the third back target label BT 3 and is activated when the logical equation of [X 3 and NOT(Y 3 )] is true at the moment of execution of the owner back branch instruction R.BBI 3 ; and a second owner forward branch OFB. 2 that extends from the resultant forward branch instruction R.FBI 3 to the third forward target label FT 3 located at the end of the Instruction sequence I, wherein the second owner forward branch OFB. 2 is activated when the logical condition Y 3 is true at the moment of execution of the resultant forward branch instruction R.FBI 3 .
Referring now to FIGS. 10A through 10C , FIGS. 10A through 10C illustrate the partial generation of the second resultant code R. 2 by replacement of toe instruction patterns of the first resultant code R. 1 with toe sets of the second resultant code R. 2 . FIG. 10A illustrates an exemplary first toe instruction pattern positioned within a second resultant instruction sequence R 1 .SEQ 2 of the first resultant sequence R. 1 . The exemplary toe instruction pattern includes a fourth forward branch instruction FBI 4 placed immediately before an instruction sequence J; a fourth back target label BT 4 located immediately after the instruction sequence J and immediately before an instruction sequence K; and a fourth forward target label FT 4 located immediately after the instruction sequence K and immediately before an instruction sequence L.
The fourth forward branch instruction FBI 4 activates a fourth forward branch FB. 4 , wherein an execution of the first resultant code R. 1 proceeds from the fourth forward branch instruction FBI 4 to the fourth forward target FT 4 when a logic condition Y 4 is determined to be true at the moment of execution of the fourth forward branch instruction FBI 4 . The fourth back branch instruction FBI 4 activates a fourth back branch BB. 4 , wherein an execution of the first resultant code R. 1 proceeds from the fourth back branch instruction BBI 4 to the fourth back target BT 4 when a logic condition X 4 is determined to be true at the moment of execution of the fourth back branch instruction BBI 4 .
The owner instruction pattern provides a fourth forward branch FB. 4 that overlaps a fourth back branch BB. 4 , wherein the fourth back branch BB. 4 is formed by a fourth back branch instruction BBI 4 that points to a fourth back target label BT 4 , and the fourth forward branch FB. 4 is formed by a fourth forward branch instruction FBI 4 that points to a fourth forward target label FT 4 . The fourth forward branch instruction FBI 4 is positioned at the beginning of the first instruction sequence R 1 .SEQ 2 and the fourth forward target label FT 4 is positioned in between the third back branch target FT 4 and the fourth back branch target FT 4 .
According to the logic of the fourth forward branch FB. 4 , a program execution of the second instruction sequence R 1 .SEQ 2 by the processor module 2 A proceeds from the fourth forward branch instruction FBI 4 to the fourth forward target label FT 4 when a logic condition of Y 4 is true at the moment of execution of the fourth forward branch instruction FBI 4 . Furthermore, according to the logic of the fourth back branch BB. 4 , a program execution of the second instruction sequence R 1 .SEQ 2 by the processor module 2 A proceeds from the fourth back branch instruction BBI 4 to the fourth back target label BT 4 when a logic condition of X 4 is true at the moment of execution of the fourth back branch instruction BBI 4 .
FIG. 10A further illustrates that an instruction sequence G is disposed between the fourth branch instruction FBI 4 and the fourth back target label BT 4 ; that an instruction sequence H is disposed between the fourth forward back label BT 4 and the fourth forward target label FT 4 ; and an instruction sequence I is disposed between the fourth forward target label FT 4 and the fourth back target instruction BBI 4 .
FIG. 10B is an Illustration of an execution of the toe algorithm that is applied in step 816 as often as required in ascending order within the resultant code R. 1 to replace toe overlap patterns with toe sets in the second resultant code R. 2 . Toward this end, system software SW. 2 or SW. 5 directs the computer 2 or 4 to seek all forward branch instructions that form a toe overlap pattern in combination with the instant back branch instruction, wherein each relevant toe pattern forward branch instruction (1.) is located in the first resultant code R. 1 after the back target label of the instant back branch instruction; and (2.) forms a toe overlap pattern in combination with the instant back branch instruction by having an associated forward target label that is located between the instant back target label and the instant back branch instruction.
According to the software-encoded toe algorithm of FIG. 10B , when a toe instruction pattern is determined in step 8 . 16 , a new resultant forward target label R.FT 4 is inserted in step 10 B. 2 immediately after the end of instruction sequence G. The fourth forward branch instruction FBI 4 is modified to point to the new resultant forward target label R.FT 4 in step 10 B. 4 and thereby to form the first toe forward branch TFB. 1 . A new first toe set instruction TI. 1 is inserted between the new resultant forward target label R.FT 4 and the fourth back target label BT 4 , wherein the first toe set instruction TI. 1 sets the condition X 4 to be true.
A new resultant toe fourth branch instruction R.FBI 4 is inserted in step 10 B. 8 , wherein the resultant toe fourth branch instruction R.FBI 4 includes logic that directs the computer to proceed to the fourth forward target label FT 4 when the following logical statement is true:
[NOT(X 4 ) or Y 4 ].
Any and all pointers and references of the first resultant code R. 1 are updated as necessary in step 10 B. 10 in view of the addition of instructions to the first resultant code R. 1 imposed by the execution of steps 10 B. 2 - 10 B. 8 .
FIG. 10C is an illustration of an exemplary application of the toe algorithm of the invented method by the software-encoded method of FIG. 10B upon the toe instruction pattern of FIG. 10A to generate the exemplary toe set of FIG. 10C of the second resultant code R. 2 . As presented in FIG. 10C , the first toe forward branch TFB. 1 of the toe set is formed by the fourth forward branch instruction FBI 4 and the fourth resultant forward target R.FT 4 . The second toe forward branch TFB. 2 of the exemplary toe set is formed by the resultant toe fourth branch instruction R.FBI 4 and the fourth forward target label FT 4 .
FIG. 11 is an illustration of a first sequence of software code S 2 .SEQ 1 of the second resultant code R. 2 that provides an overlapping pair of forward branches FB. 1 & FB. 2 . The first sequence of software code S 2 .SEQ 1 includes a forward overlap pattern composed of a first forward branch instruction FBI 1 and a second forward branch instruction FBI 2 , wherein the first forward branch instruction FBI 1 points to a first forward target label FT 1 that is located between the second forward branch instruction FBI 2 and a second forward target label FT 2 to which the second forward branch instruction FBI 2 points. The first forward branch instruction FBI 1 is located immediately before an instruction sequence J and the second forward branch instruction FBI 2 is located immediately after the instruction sequence J. A sequence K of code is disposed immediately after the second forward branch instruction FBI 2 and immediately before the first target label FT 1 . An instruction sequence L is disposed immediately between the first target label FT 1 and the second target label FT 2 .
FIG. 12A is a flow chart of a portion of the first system software SW. 2 and the second system software SW. 5 that in the generation of a third resultant code R. 3 replaces the forward overlap patterns of FIG. 11 with a forward set of FIG. 12C and thereby remove the overlapping forward branches from the sequence of instructions 4000 - 4999 SEQ from the second resultant code R. 2 . A current line value CRNT and a last line value END are initialized in step 12 A. 02 wherein the current line value CRNT is equal to the value of the first line of code 4000 of the sequence of instructions 4000 - 4999 SEQ and the last line value END is set equal to the last line of code 4999 of the sequence of instructions 4000 - 4999 SEQ. In step 12 A. 04 the computer 2 determines if the current line value CRNT has been incremented by cycling through the loop of steps 12 A. 10 through 12 A. 22 to be made equal to or greater than the last line value END of 4999 . When the computer 2 determines in step 12 A. 04 that the current line value CRNT has been incremented to be equal to or greater than the last line value END, the computer 2 proceeds on to store the software code modified by execution of steps 12 A. 04 through 12 A. 22 as a third resultant code R. 3 , and proceeds from step 12 A. 06 to step 12 A. 08 and to perform alternate computational operations.
When the computer 2 determines in step 12 A. 04 that the code line value CRNT of the sequence of instructions 4000 - 4999 SEQ is less than the last line value END, the computer 2 proceeds on to step 12 A. 10 to determine if software code at line value CRNT provides a forward branch instruction. When the computer 2 determines in step 12 A. 10 that the software code at line value CRNT is not a forward branch instruction, the computer 2 proceeds onto step 12 A. 12 and to increment the current line value CRNT. The computer 2 proceeds from step 12 A. 12 to an additional execution of step 12 A. 04 .
Alternately, when the computer 2 determines in step 12 A. 10 that the software code at line value CRNT is a forward branch instruction, the computer 2 proceeds onto step 12 A. 14 and to seek a first instance of an overlapping additional forward branch instruction FBI 2 , or “OBB”, positioned between a forward branch instruction FBI 1 determined in the last instance of step 12 A. 10 and a first forward target label FT 1 as specified by the first forward branch instruction FBI 1 . When an overlapping second forward branch instruction FBI 22 is not found by the computer 2 within the sequence of instructions found between the first forward branch instruction FBI 1 and the first forward target label FT 1 in step 12 A. 16 , the computer 2 proceeds onto step 12 A. 12 and therefrom onto step 12 A. 04 .
When an overlapping forward branch instruction FBI 2 is found in step 12 A. 16 , the forward algorithm is applied in step 12 A. 18 as illustrated in FIG. 12B . The computer 2 or 4 proceeds from step 12 A. 18 to step 12 A. 20 in the process of generating the third resultant code R. 3 and to update all pointers and references within the source program SW. 3 that have been altered by the modifications of the instruction sequence 4000 - 4999 SEQ in the most recent instance of step 12 A. 18 .
FIG. 12B is a flow chart of a software-encoded application of the third optional aspect of the invented method that removes a forward instruction pattern from a second resultant R. 2 software and replaces the forward instruction pattern with a logically equivalent forward set in the third resultant code R. 3 . In step 12 B. 02 the second forward branch instruction FBI 2 is modified to point to the first forward target label FT 1 to which the first forward branch instruction FBI 1 also points.
In step 12 B. 04 the a new third resultant forward branch instruction R.FBI 3 is inserted between the first forward target label FT 1 and the sequence L, wherein the third resultant forward branch instruction R.FBI 3 directs the computer 2 or 4 to proceed directly on to the first forward target label FT 1 when the logic condition of Y 2 is TRUE.
FIG. 12C is an illustration of the forward set as generated by the method of FIG. 2B as an element of the third resultant code R. 3 , wherein the first forward branch FB. 1 of the forward instruction pattern, a second resultant branch R.FB. 2 and a third resultant forward branch R.FB. 3 provide logic equivalent to the originating forward instruction pattern of FIG. 11 .
FIG. 13 is a flow chart of a successive application of the first four aspects of the invented method to the sequential instructions 4000 - 4999 SEQ that are used to generate a final resultant code R. 3 . The source program SW. 3 is acquired by the computer 2 or the reconfigurable computer 4 in step 13 . 2 The first aspect of the invented method of FIG. 6 is applied in step 13 . 4 to the entire instruction sequence 4000 - 4999 SEQ of the source program SW. 3 in an ascending order from instruction 4999 to instruction 4000 to generate a first resultant code R. 1 , whereby the first resultant code R. 1 is generated and all overlapping back branches of the source program SW. 3 are transformed within the first resultant code R. 1 into either nested branches or unrelated branches.
The third aspect of the invented method of FIG. 10 and the fourth aspect of the invented method of FIG. 12 are applied in step 13 . 6 to the entire instruction sequence 4000 - 4999 SEQ of the first resultant code R. 1 in an ascending order from instruction 4999 to instruction 4000 to generate a second resultant code R. 2 , whereby overlapping forward and back branches are transformed within the second resultant code R. 2 into either nested branches or unrelated branches.
The second aspect of the invented method of FIG. 8 is applied in step 13 . 8 to the entire instruction sequence 4000 - 4999 SEQ of the second resultant code R. 2 in an descending order from instruction 4000 to instruction 4999 to generate a final resultant code R. 3 , whereby overlapping forward branches are transformed within the final resultant code R. 3 into either nested branches or unrelated branches.
FIG. 14 is a process chart of a derivation of final resultant code R. 3 and application of the final resultant code R. 3 by the computer 2 , the reconfigurable computer 4 and/or the network 3 . In step 14 . 2 is input into the computer 2 , the reconfigurable computer 4 and/or the network 3 . It is understood when the process of FIG. 14 is applied by the network 3 , that the source program SW. 3 is isolated into portions and the portions are distributed among systems 2 , 3 C & 4 of the network 3 . When the process of FIG. 14 is applied by the reconfigurable computer 4 , optional step 14 . 4 is applied wherein the RLC 4 A of the reconfigurable computer 4 may be configured or programmed to process the source program SW. 3 . The final resultant code R. 3 generated by the method of FIG. 13 in step 14 . 6 . The final resultant code R. 3 is then input (if not already present within) the reconfigurable computer 4 in step 14 . 8 , and the final resultant code R. 3 is executed by the reconfigurable computer 4 with participation by the RLC 4 A in step 14 . 10 .
The foregoing disclosures and statements are illustrative only of the Present Invention, and are not intended to limit or define the scope of the Present Invention. The above description is intended to be illustrative, and not restrictive. Although the examples given include many specificities, they are intended as illustrative of only certain possible configurations or aspects of the Present Invention. The examples given should only be interpreted as illustrations of some of the preferred configurations or aspects of the Present Invention, and the full scope of the Present Invention should be determined by the appended claims and their legal equivalents. Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiments can be configured without departing from the scope and spirit of the Present Invention. Therefore, it is to be understood that the Present Invention may be practiced other than as specifically described herein. The scope of the present invention as disclosed and claimed should, therefore, be determined with reference to the knowledge of one skilled in the art and in light of the disclosures presented above. | A method and system are provided for deriving a resultant software program from an originating software program having overlapping branches, wherein the resultant software project has either no overlapping branches or fewer overlapping branches than the originating software program. A preferred embodiment of the invented method generates a resultant software program that has no overlapping branches. The resultant software is more easily converted into programming reconfigurable logic than the originating software program. Separate and individually applicable aspects of the invented method are used to eliminate all four possible states of two overlapping branches, i.e., forward branch overlapping forward branch, back branch overlapping back branch, and each of the two possible and distinguishable states of forward branch and back branch overlap. One or more elements of each aspect of the invention may be performed by one or more computers or processors, or by means of a computer or a communications network. | 6 |
CROSS REFERENCE TO RELATED INVENTIONS
[0001] This application is a continuation-in-part of and claims priority to U.S. Nonprovisional application Ser. No. 13/374,229 filed Dec. 11, 2011 by Torek Thompkins. The specification of this application is incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The embodiments of the present invention relate generally to the field of energy generation.
COPYRIGHT
[0003] Copyright—A portion of the disclosure of this document contains material that 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 publically available Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. The following notice applies to the software, data, and/or screenshots which may be described below and in the drawings that form a part of this document: Copyright Torek Al-Amin Thompkins, All Rights Reserved.
BACKGROUND
[0004] Generators for producing energy work by collecting and converting kinetic energy created through mechanical means such as a spinning action. Windmills are an example. There have also been attempts to generate energy based on the movement of vehicles.
[0005] One type of device for electricity generation in motor vehicles makes use of a ground engagement wheel. For instance, U.S. Pat. No. 5,921,334 to Al Dokhi claims a ground dragging wheel on the undercarriage of a vehicle connected to a pulley operating to spin the shaft of a generator. This configuration requires movement of the vehicle in order to produce energy. U.S. Pat. No. 5,680,907 to Weihe discloses a similar ground engagement wheel as Al-Dokhi except that the ground engagement wheel is used simply as a gear to move the vehicle wheel, not for producing energy (the wheel is itself powered by solar panels on the roof of the vehicle claimed).
[0006] Another example of electrical generation from vehicles is regenerative braking. These systems only create energy while braking or going downhill.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a detailed view of an embodiment of the wheelmill of the device.
[0008] FIG. 2 is a view of the wheelmill showing connectivity to a shaft in accordance with an embodiment of the device.
[0009] FIG. 3 shows the device mounted to a vehicle in accordance with an embodiment.
[0010] FIG. 4 shows a detailed view of the wheelmill of the device showing a one way clutch in accordance with an embodiment.
[0011] FIG. 5 is a view of the device showing rotation on the wheel of a vehicle and the shaft of the wheelmill, in accordance with an embodiment.
[0012] FIG. 6 is a view of the wheelmill in communication with a wheel, showing the axes of the wheel and wheelmill and rotation of both, in accordance with an embodiment.
[0013] FIG. 7 is an alternate view of the wheelmill in communication with a wheel in accordance with an embodiment.
[0014] FIG. 8 is a view showing the device installed on a vehicle in accordance with an embodiment.
[0015] FIG. 9 shows an alternate embodiment of the wheelmill showing flexible shock absorbing spokes within the wheelmill body.
DETAILED DESCRIPTION
[0016] Disclosed is an improved device for generating energy. When coupled with the wheel of a vehicle, the device produces energy even when the vehicle has stopped or is moving in reverse. The device generates energy when vehicle stops/reverses if its previous momentum has not yet dissipated. The device preferably comprises a generator and wheelmill having an opening for receiving a shaft of the generator, such that the rotation of the wheelmill results in the generation of energy by the device. The device is adapted for mounting on a vehicle such that the wheelmill contacts the inner surface of a wheel of a vehicle. The generator and shaft connecting the generator to the wheelmill are preferably mounted to the vehicle's undercarriage. Improvements include a one-way clutch which allows wheelmill to spin bidirectionally while negating the connected shaft from backspin. The device improves on previous techniques for generation of energy from the movement of a vehicle wheel. The improvements include the adaptation for attachment to the inner surface of the wheel and configuration permitting rotation of the wheelmill in one direction only. This configuration is advantageous because it allows for more efficient energy production, as described below. This disclosure will first address the construction of the device. Next, it will explain how the device operates to produce energy.
[0017] The device disclosed may be a wheelmill coupled with a shaft and generator or the wheelmill alone. FIG. 1 shows the preferred embodiment of wheelmill 101 of the device. Wheelmill 101 is shaped like a wheel and is preferably comprised of a one way clutch 103 surrounded by the wheelmill's inner rim 105 . Inner rim 105 may be a rigid metal, hollow or solid. The material used may be aluminum because it dissipates heat well and is lightweight, however a heavier material may be used. Inner rim 105 is in movable communication with and surrounded by body 107 . The inner rim 105 serves to put the one way clutch 103 in communication with the body 107 , however, body may be in direct communication with clutch 103 as shown in FIG. 2 . Body 107 may be solid rubberized material with tread on its outer surface 109 , 209 .
[0018] Clutch 103 may be any one way clutch known in the art for allowing the disengagement of the shaft spin when the vehicle wheel slows or stops. Transposed within clutch 103 , there is preferably a threaded inlet 111 so that a shaft 201 may be screwed into cavity 203 (which is preferably centrally located) through the opening 211 in the threaded inlet 111 , FIG. 2 shows an embodiment of the wheelmill 101 where body 107 , 205 are in direct communication with clutch 103 , 207 . As depicted, clutch 207 is transposed within body 205 such that its depth within body 205 is half the depth of body 207 . However, clutch 207 may transpose the length of the body 207 in other embodiments. While a screw mechanism is present in the preferred embodiment, alternate connection means for communicating the shaft to the wheelmill known in the art are anticipated and may be used.
[0019] FIG. 3 shows the device attached to a vehicle. Although the vehicle shown in FIG. 3 is an automobile, the term “vehicle” for the purpose of this disclosure shall mean any device having at least one wheel which may move in at least a forward direction through mechanical or electrical means. In the preferred embodiment, “vehicle” refers to an automobile (powered by either electricity, an internal combustion engine or a combination of both), however vehicle may refer to a scooter, motorcycle, Segway, or even bicycle or unicycle.
[0020] The device preferably comprises wheelmill 301 and generator 303 , in communication via shaft 305 . The shaft 305 is rotatably connected to generator 303 , such as a rotor shaft, such that the rotation of the shaft 305 also drives the generator to produce energy. FIG. 3 also shows the device adapted such that wheelmill 301 is placed on the outer circumference of the vehicle's wheel 308 . Generator 303 is connected to the vehicle, preferably on vehicle frame 309 . Connections 311 may be any connections known in the art for attaching generator 303 to the vehicle frame 309 . Connections may be metal fasteners with screws 313 attaching generator 303 to the vehicle frame 309 .
[0021] The wheelmill 101 , 301 attaches to a shaft 305 preferably via screw fastened in the threaded inlet 111 , 315 , which in turn is connected to a generator 303 . Generator 303 is described in more detail below, however, it is a standard generator know in the art for producing energy. It should be noted that an alternator may also be used. Generator 303 is preferably coupled with at least one battery for storing the energy generated by the generator 303 . Alternatively, generator 303 may be in communication with the vehicle's battery for return of the energy to the vehicle. Such connections between the generator 303 and a battery or other energy storage would be via electrical wiring with respective negative and positive leads for attachment to a battery. The shaft is a solid piece of metal, such as steel. This shaft rotatably communicates with generator 303 .
[0022] The configuration of the device allows for the continued production of energy even when the vehicle stops or is in reverse. In other words, the device permits the harnessing of residual momentum due to the forward rotation of the shaft to produce energy even if the vehicle wheel has stopped. The one way clutch 103 allows the shaft 201 to continue to spin even when the car is slowing down or there is a sudden brake, thereby negating of the backspin of the shaft when the car is in reverse or when the car slows. The shaft 201 will continue to spin so as to generate electricity in the generator 303 even when the body 107 and inner rim 105 of the wheelmill spinning slows or stops due to the vehicle's change in forward motion. In the case of a sudden braking, the body 107 and inner rim 105 will slow or stop moving in accordance with the vehicle's wheel movement; however, because the one way clutch will disengage in that event, hub 417 will continue its forward motion (therefore shaft 201 will continue to spin to create electricity generation) until the momentum created by the previous forward drive dissipates or the vehicle wheel re-engages at a forward spin at a rate higher than the then-present shaft spin. This means that electrical generation continues until either the momentum dissipates, or more forward drive is applied that increases the body 401 revolutions. Another advantage to the disclosed configuration is that the forward momentum of the spinning shaft does not interfere with or negate the car wheel itself coming to a stop or slowing down.
[0023] FIG. 4 is another view of the wheelmill of the device depicting arrows to show movement of the various components of the wheelmill. Hub 417 is another term to describe the location of the one way clutch which moves independently of inner rim 411 , 105 and body 401 , 107 when the vehicle's wheel slows or stops—allowing the shaft to continue to spin to produce electricity within the generator 303 , even when the vehicle slows or stops. A racheted one way clutch is shown, but other types of one way clutch for disengaging the shaft rotation from the body 401 rotation may be used, such as the racheted one way clutch systems used in bicycles allowing for the continued rotation of the wheels when the driver has stopped pedaling. All three components 405 , 105 , and 107 move in the same direction when the vehicle is moving forward. This is because paw 415 locks against the rachets when the wheel (and therefore body 401 ) are moving in the clockwise direction, A. Components 105 and 107 move together in both forward and reverse movement.
[0024] FIG. 5 shows another view of the device mounted to a wheel arm 501 and also showing the rotation of the wheel 503 and wheelmill 100 , respectively. Generator 505 is preferably attached to wheel arm on the vehicle. In most vehicles, the wheel sits on a shock absorption component under the car. As the shocks move up and down, the wheel arm moves in conjunction with this movement. Therefore, the preferred connection of the generator will be to the wheel arm 501 . This will allow for movement of the device in harmony with the vehicle as the vehicle encounters irregular road surface conditions, such as bumps or potholes. Generator 505 may also be fixedly or removably mounted to other portions of the undercarriage, such as a vehicle frame.
[0025] The preferred construction of the wheelmill body is at least partially a rubberized material on the outer surface of body 109 . Body 109 may also be metal or a combination of metal and a rubberized material. Body 109 may also be any material with give so as to absorb shock. Body 109 may also have a grooved surface similar to a tire for providing increased traction for receiving the rotational push from the vehicle wheel. When the vehicle encounters bumps on the road, the rubber will still be firm enough to be rotated by the vehicle's wheel, but also compress slightly when encountering a bump—without interruption of spin.
[0026] FIG. 8 shows the preferred embodiment of the device such that the wheelmill 801 is in communication with the inside surface 803 of the wheel 805 . This Figure also shows an alternate view of rotatable shaft 807 in communication with generator 809 , mounted to the vehicle undercarriage 811 via mounting plate 813 . Other connection means may be used, and the generator may also be in communication with a battery for storage, or supply energy directly to the vehicle. This figure also shows the unique location of wheelmill 801 , as it makes use of the inner surface 803 of the outer circumference of the wheel 805 to push the wheelmill so as to rotate it, and subsequently the shaft 807 , so as to produce electricity within generator 811 .
[0027] Because the wheelmill is pushed by the force exerted by the moving wheel at the place where the wheelmill is in contact with the wheel, it will spin and draw from the torque produced by the wheel. The advantage of the device is that the device will produce more energy from the rotation of the wheel than can be produced by the wheel itself. This is because the circumference of the wheelmill is smaller than the wheel, and therefore can complete revolutions at a higher rate than the vehicle wheel.
[0028] FIG. 9 is an example alternate embodiment of the wheelmill 900 where the wheelmill 900 is constructed of flexible, preferably rubberized, material. The flexible nature of the outer wall 901 of the wheelmill may be accomplished also by the use of flexible spokes 903 connecting the outer wall 901 to an inner wall 905 , where the outer wall 901 is constructed of flexible, preferably rubberized material. The advantage to this construction is that the outer portion of the wheelmill may compress and decompress when the wheelmill subjected to jostling forces (such as when the vehicle is driving forward on bumpy terrain) while still allowing the shaft (in communication with wheelmill 900 at point 907 ) to continue to spin.
[0029] The configuration of the disclosed device simplifies the structure and increases the stability of devices for collecting energy from the movement of motor vehicles. For example, the device directly connects the spinning shaft with the rotation of the wheel of the vehicle, due to the communication of wheelmill directly with the wheel. Devices which make use of pulley systems are not as efficient, as any transfer of mechanical force from one component to another naturally results in loss of energy. Another advantage is that the device's wheelmill is configured for placement on the inner circumference of the wheel. Not only does this allow for a more direct communication between shaft rotation and wheel rotation obviating the need for pulleys and additional gears, it also protects the wheelmill from nonuniform environments present in a ground engagement system. For instance, a ground engagement wheel may traverse over sand and momentarily cease rotating (and simply drag). In that event, there can be no power generation. In contrast, the wheelmill is exposed to a uniform environment, the inside of the wheel. The wheelmill will therefore only cease spinning if there is no more forward drive and the residual forward momentum has dissipated.
[0030] FIG. 6 is shown to illustrate the way in which the device generates energy from the wheel in excess of the energy that could be produced if a generator and shaft were attached to the wheel itself. The main reason is that the device's wheelmill makes more revolutions per unit time, thus generating more energy at a generator having a given torque than would the wheel itself.
[0031] An example is provided in reference to FIG. 6 : Imagine circle (A) is an 18″ diameter wheel rim, and circle (B) is a 2″ diameter wheelmill. The rotational axis of (A) is (a). The rotational axis of (B) is (b). When circle (A) rotates clockwise, traction between its inner surface (C), rolls circle (B) in the same clockwise direction. Because circle (B) is 9 times smaller than circle (A), it can complete a 360 degree turn, 9 times more than (A). Therefore, for every revolution of circle (A), circle (B) is rolled 9 times. The number of revolutions is measured by RPMs and is related to power and torque via the equation, Power=RPMs×Torque/5252.
[0032] FIG. 7 is provided to illustrate a sample calculation of power output and comparison between the wheel v. wheelmill energy output and production. One difference is that RPMs for a wheel and the wheelmill are different. Circle (A) represents a vehicle wheel rim moving forward, revolving clockwise. The vehicle uses torque coupled with RPMs (horsepower) to turn the rim (A). The direction of vehicle torque (D) is used to propel the vehicle forward. A portion of the vehicle's torque is used to rotate the wheelmill (B), which is connected to the shaft of a generator. Torque resistance of (B) is determined by the ratings of the connected generator. Opposing force of the wheelmill (B) is represented by arrow (E). In this comparison, we assume the vehicle is driven 40 miles in one hour, by a 200 lb-ft torque flat curve electric motor, with an attached wheelmill generator rated 5 kW at 6726 rpms.
[0000]
Vehicle power output vs. Wheemill production:
Vehicle
vs.
Wheelmill device
Torque
200 lb-ft
5.2 lb-ft
RPMs
747 rpm
6726 rpm
Torque
×
RPMs = Power (horsepower, hp)
Power loss to wheelmill
5.2 lb-ft
@
747 = .74 hp/hr
Wheelmill production
5.2 lb-ft
@
6726 = 6.7 hp/hr
[0033] This example shows a wheelmill production of 6.7 hp, for the cost of 0.74 hp.
[0034] The vehicle loses an extra 0.74 hp in 1 hour towards turning the wheelmill (B). Wheelmill (B) produces 6.7 hp in that same 1 hour. Therefore, the Power gain=5.96 hp.
[0035] The above examples and embodiments have been provided, however the inventive concepts disclosed may be otherwise variously embodied and employed. | A device is disclosed comprising a wheelmill having a cylindrical shape adapted to receive a rotatable shaft of a generator and a one way clutch housed within the inner portion of the wheelmill in communication with the shaft such that said shaft may rotate in one direction only and a generator in communication with the shaft. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of my co-pending patent application Ser. No. 120,277 filed Feb. 11, 1980, now abandoned.
BACKGROUND OF THE INVENTION
Most liquid products, until fairly recently, have been machine-loaded into cans and jars using gravity, rotary, or vacuum methods. All of these methods exhibit certain speed limitations in the loading operation. In response to this problem, the positive displacement filling machine was developed, and to a certain extent has proved quite successful. The positive displacement approach calls for a device, generally using a reciprocating piston assembly, capable of rapid-fire injection of predetermined amounts of the product into storage containers.
The early positive displacement machines, such as the apparatus disclosed in my U.S. Pat. No. 3,358,719 issued Dec. 19, 1967, were designed primarily to load liquid products of a heavier nature, ranging from paste-like products to medium viscosity fluids containing solid particles. While these products proved viscous enough to permit earlier designs to operate without a special nozzle apparatus, the low viscosity, water-thin products posed special problems.
Contaminating product drip between load bursts and irregularities in fill quantities plagued low viscosity fluid loading operations. These problems were especially evident if the filling machine slowed in operating speed or stopped entirely during loading. Without secondary valve means to inhibit unwanted discharge flow, the water liquid would drain from the metering pocket faster than the displacing piston could pump it out, and overfill the container. The low viscosity fluid also collected upon the nozzle surface and occasionally dripped onto the upper sealing edge of the cans, contaminating the entire contents.
The patent to Kerr, U.S. Pat. No. 3,096,914 represents an attempt to provide a secondary valve means designed to solve the aforementioned difficulties. The design is deficient in that it relies on the presence of a partial vacuum above the diaphragm to form a proper seal against leakage.
In short, the resiliency of the diaphragm itself is not sufficient to form an effective seal during all phases of the loading cycle. For example, if the machine were slowed or stopped during the downward, compression stroke of the piston, the pressure above the diaphragm would naturally exeed the atmospheric pressure. Using a secondary valve constructed in accordance with the Kerr design, a positive seal against dribble or leak could not exist under such conditions.
The invention disclosed herein, while using diaphragm construction in its valve mechanism, is designed to provide a complete seal against undesirable leakage during all phases of the loading cycle. Extremely resilient diaphragm construction cooperates with a unique nozzle design, resulting in a pressure-actuated valve which overcomes the deficiencies inherent in known prior art.
SUMMARY OF THE INVENTION
A hollow cylinder, which threads onto the discharge outlet of a conventional positive displacement filling machine, houses a pressure-actuated valve mechanism.
Situated within the hollow cylinder, in one form of the device, as shown in FIGS. 1-5, is an axially centered, transverse, annular diaphragm secured around the periphery and having a central aperture. An axially coincident cylindrical plug includes a central conical hub which projects downwardly into abutment with the central portion of the resilient annular diaphragm, deforming the annular portion downwardly, as appears in FIG. 1. A tight seal is thereby maintained during fluid cut-off between the upper edge portion of the annular aperture walls and the lower surface of the impinging conical hub.
A plurality of discharge apertures extends through the body of the plug around the conical hub, from the upper to the lower surface. The positive displacement filling machine produces a continuous series of pulsating discharges through the discharge outlet and upon the upper surfaces of the plug and conical hub. The pressures generated are such that the liquid is vigorously urged downwardly through the plurality of discharge apertures and into the small chamber defined by the upper surface of the diaphragm and the lower surfaces of the plug and conical hub. In response to each respective pulse, the annular aperture in the diaphragm deforms farther downwardly, as shown in FIG. 2, slightly separating from the conical hub to allow the liquid to spurt therethrough. Following each pressure burst, the aperture immediately reforms in tight relation about the conical hub to renew the seal.
In a modified and preferred form of device, as disclosed in FIGS. 6-9, the central portion of the diaphragm is fixed and it is the rim or peripheral portion which flexes open or shut in dependence upon the fluid pulses. During fluid cut-off the diaphragm rim is tightly sealed against an adjacent circular corner edge located at the bottom of the plug, as in FIG. 6.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a median, vertical sectional view through a filling station of a positive displacement, reciprocating piston filling machine with the flow control apparatus attached to the lower end of the discharge outlet, with the diaphragm valve being of annular configuration and shown in closed position;
FIG. 2 is a median, vertical sectional view through a filling station as in FIG. 1, but with the annular diaphragm valve in open position for discharging the liquid product;
FIG. 3 is a horizontal, sectional view taken along the line 3--3 of FIG. 2, showing the plurality of discharge apertures in the upper surface of the cylindrical plug around the central conical hub;
FIG. 4 is a vertical, sectional view of the annular diaphragm, taken on a diameter thereof;
FIG. 5 is a top plan view of the annular diaphragm;
FIG. 6 is a vertical cross-section of a modified form of filling station using a rim flexing diaphragm, and showing the diaphragm in closed position;
FIG. 7 is a view similar to that of FIG. 6 but with the diaphragm flexed open, allowing the product to pass over the outer edge of the diaphragm, and with some of the shading removed to clarify the disclosure;
FIG. 8 is a horizontal sectional view taken on the plane indicated by the line 8--8 in FIG. 6; and,
FIG. 9 is an exploded sectional view of the preferred embodiment of the valve of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The valve 11 of the invention is threadably attached to an outlet bushing 12, or valve upper body, of a receptable filling machine 13, including a base frame. U.S. Pat. No. 3,358,719, issued Dec. 19, 1967 to E. S. Minard, to which reference may be had, teaches the structure and operation of a similar filling machine.
As most clearly appears in FIG. 1 herein a product reservoir 14, defined by container 15, provides a ready supply of liquid product to be loaded. An inlet port 16 in the floor of reservoir 14 extending along a vertical axis, forms part of a dispensing channel and communicates with a lateral passageway 17 in valve port housing 18. An upstanding cylinder 19 is positioned over the lateral extension of the valve port housing 18 and communicates with lateral passageway 17. A piston 21 slidably engages the inner wall of the cylinder 19.
A valve stem assembly, generally designated 22, comprises a stem 23, an upper guide bar 24, an upper movable plug 26, a stem extension 27, and a lower movable plug 28. Outlet bushing 12, or valve upper body, includes an outlet port 29, also extending along the axis and forming another part of the dispensing channel, axially coincident with inlet port 16.
With valve stem assembly 22 in its lowermost position, as shown in FIG. 1, the lower moveable plug 28 is slidably engaged with the outlet port 29 and the bevel seat 31 of stem extension 27 is in flush engagement with the inclined upper surface of outlet bushing 12.
FIG. 2 illustrates valve stem assembly 22 in its uppermost position. Upper movable plug 26 is slidably engaged with inlet port 16 and lower movable plug 28 is entirely withdrawn from outlet port 29. The length of stem extension 27 is such that upper movable plug 26 will enter inlet port 16 just prior to the complete removal of lower movable plug 28 from outlet port 29. Since at least one or the other of the movable plugs is engaged with its respective port at all times during the reciprocating vertical motion of valve stem assembly 22, accurate alignment of the stem is maintained throughout the cycle. Guide bar housing 32 is flange-mounted upon casing 15 and assures proper alignment of the upper portion of the stem.
Reciprocating motion along a vertical axis is applied to stem roller 33 and cylinder roller 34 by cam means of conventional design. Roller 33 and roller 34 are rotatably attached to stem bar 36 and cylinder bar 37, respectively. Bars 36 and 37 are, in turn, laterally attached to upper guide bar 24 and piston 21, and slide within groove 38 and channel 39, respectively. Thus, valve stem assembly 22 and piston 21 are raised and lowered in timed relationship by appropriate cam means.
The positive displacement filling machine 13 produces at outlet port 29, sequential bursts of a predetermined amount of liquid product. It will be noted that FIG. 1 illustrates the position of the valve stem assembly 22 and piston 21 when product stored in reservoir 14 flows through the inlet port 16 into lateral passageway 17. FIG. 2 shows the valve stem assembly 22 in its raised position, sealing off inlet port 16 and exposing discharge port 29. Piston 21 (not shown in FIG. 2) is descending, driving the product through discharge port 29. Thus, FIGS. 1 and 2 depict the loading and discharge phases of the positive displacement filling machine 13, respectively (also see E. S. Minard U.S. Pat. No. 3,358,719).
The valve 11 of the invention interposed between outlet bushing 12 and a container 41, or receptacle, generally comprises an interiorly threaded discharge nut 42, or nozzle fitting, or outlet body, including wrench flats 43 to facilitate addition to as well as removal of the device from the filling machine. Since filling machines are used for loading fluids of varying viscosities and the device 11 is not necessary when loading with very high viscosity products, quidk and easy removal of the fitting is a desirable feature.
Axially coincident within the nozzle fitting 42 are a fixed cylindrical plug 44, or ring, and an elastomeric diaphragm 46, or valve annulus. As can be seen most clearly in FIGS. 2 and 3, the fixed cylindrical plug 44 fits within a bore 47 formed in the nozzle fitting 42. The flexible diaphragm 46, positioned immediately beneath fixed plug 44 in a bore 45, includes an upper marginal rim 48 (FIG. 2), having a transverse surface disposed at a predetermined elevation, and a lower marginal rim 49. When the device of the invention is initially assembled, the resilient diaphragm 46 is laid within the bore 45 and the lower rim 49 mates with an annular groove 51 in the nozzle fitting 42.
Then, the fixed cylindrical plug 44 is dropped into position, and the upper rim 48 nests within an annular groove 52 in the fixed plug 44. The rim and groove construction ensures that the diaphragm 46 remains axially coincident with the superposed fixed cylindrical plug 44 and accurately flexes under the forces applied.
The core of the fixed cylindrical plug 44 comprises a centrally positioned upper cone 53 and lower cone 54, or central cone body, both encircled by a plurality of discharge apertures 56 leaving cone supporting arms between them. As the device is threaded onto the outlet bushing 12, the lower cone 54 intrudes through an annular aperture 57 defined by a cylindrical wall in the undistorted diaphragm 46. When the valve is fully seated, cylindrical plug 44 snugly locks diaphragm 46 into position and lower cone 54 downwardly depresses the upper edge or sealing corner of the annular aperture 57, to acquire a predetermined diameter as illustrated in FIG. 1. Owing to the considerable resiliency of diaphragm 46, a tight seal is formed by the interface between the upper edge of the diaphragm 46 at the annular aperture 57 and the adjacent surface of the lower cone 54, as shown in FIG. 1.
As the filling machine 13 progresses through its load cycle, sequential bursts of liquid product are first forced downwardly through outlet port 29, then are radially distributed by the upper cone 53 before travelling down through the plurality of discharge apertures 56. The product then enters a circular chamber 58, which interconnects all the discharge apertures 56. The circular chamber 58 introduces the liquid product against the upper surface of diaphragm 46, urging the inner portion of the diaphragm, near the annular aperture 57, downwardly and slightly away from the lower cone 54. A conical wall 59 is disposed to allow adequate space for the diaphragm 46 to flex during the fill phase of the loading cycle. FIG. 2 clearly shows an extreme flexed position the diaphragm 46 assumes when permitting fluid product to pass downwardly through discharge port 61 and into the container 41.
Upon completion of the load burst, the diaphragm 46 rapidly returns to a snug sealing relation with the lower cone 54, as shown in FIG. 1, thereby preventing product drip. Valve stem assembly 22 again reciprocates to its lowermost position, permitting fluid product to flow from reservoir 14 into lateral passageway 17.
Stem assembly 22 must now again be raised to seal the inlet port 16. A vertical hole 62 and a horizontal hole 63 are provided in the movable lower plug 28 to facilitate this return trip of the stem assembly. Vertical hole 62 and horizontal hole 63 act to equalize the pressure between lateral passageway 17 and the void created when the movable lower plug 28 is withdrawn.
Should the filling machine stop or slow down during a loading period, the diaphragm 46 will act in a consistent manner. Since the diaphragm will only permit passages of fluid if a threshold pressure is present, a tight seal will immediately form if adequate pressure is not supplied by the displacement piston 21. In other words, if the piston stops its downward travel, the valve 11 will quickly seal the inner chambers of the filling machine, preventing overfill.
If the piston merely slows down in operation, the valve 11, will respond by permitting fluid to emerge only in proportion to the decreased speed and the resultant decreased pressure. Thus, it can be seen that the valve performs in an eminently satisfactory fashion, overcoming long standing problems associated with mechanical filling of containers with low viscosity products.
Although the valve 11 heretofore disclosed produces a well-formed discharge stream that cuts off sharply at the close of the filling cycle, and is drip-free following closing, the velocity of the product stream emerging from the centrally flexed annular diaphragm 46 is so great, when the machine is operating at the high fill-speeds presently utilized in the industry, that some of the product tends to splash over the rim of the container when it first strikes the bottom.
To obviate this splash problem, reduction in fill-speed must be made. With the present-day high costs of labor, materials and equipment, a reduction in fill-speed becomes expensive.
In order to overcome this obstacle to achieving maximum efficiency, the diaphragm structure and operation, as well as the housing, has beem modified, as most clearly appears in FIGS. 6-9.
In this preferred embodiment, the low viscosity fluid product passes around the outer rim of the diaphragm into a small chamber directly below the diaphragm where the velocity of the product is reduced and the stream reformed into a central flow. This stream emerges from the housing as a relatively sluggish, easy flowing but wide stream that eliminates all splashing, yet provides a sharp cut-off and drip-free operation.
Operation is still further improved by providing a disc of screen mesh across the discharge opening as will subsequently be described in detail.
The improved valve assembly 70 of the invention is threadably attached, as before, to the outlet bushing 12, or valve upper body, of a positive displacement filling machine 13, and includes an interiorly threaded discharge nut 71, or nozzle fitting, or valve lower body, having wrench flats 72 to facilitate installation and removal.
Axially coincident within the nozzle fitting 71 are a fixed cylindrical plug 75 and an elastomeric diaphragm 76. As can be seen most clearly in FIGS. 6 and 7, the fixed cylindrical plug 75 includes an outer ring 88 which fits within a bore 77 formed in the nozzle fitting 71. The diaphragm 76, positioned immediately beneath the plug 75 is tightly secured thereto by a screw 78 that passes through a central hole 79 in the plug 75 and through a central hole 80 in the diaphragm 76 and into a generally conical-shaped nut 81, or downwardly tapered nut 82 with arcuately concave side walls 82 when viewed in profile (see FIG. 9).
A centering boss 85, on the upper end of the nut 81, centers the diaphragm 76 with the plug 75; and an annular shoulder 83, or flange, on the nut 81 serves to hold the diaphragm tightly against a central hub 86 of the plug 75. The central hub 86 is positioned a predetermined distance above the lower face 87 of the outer ring 88 of the plug 75. The diaphragm 76 is of predetermined configuration approximately as shown, so it flexes to a partially spherical shape when tightly attached to the plug 75 as illustrated in FIG. 6. This flexing of the diaphragm 76 creates a force within the diaphragm so that the outer rim of the diaphragm makes a liquid-tight seal against the adjacent corner edge 84 of the lower face 87 of the ring 88 holding against a pressure of 3/4 lb. per inch. The upper portion of the ring 88 encompasses an upper manifold chamber 73 and the top of the ring 88 engages the annular seat 74 at the bottom of the upper valve body 12.
The central hub 86 is attached to the outer ring 88 by a plate 89 which has a plurality of apertures 90 through which the liquid product passes into a lower manifold chamber 100 marginally defined by the lower portion of the ring 88 to engage the upper face of the diaphragm 76.
The nozzle fitting 71 has a downwardly converging conical wall 91 located below the diaphragm and forming a chamber 93, the upper portion of which surrounds the outer rim 92, or periphery, of the diaphragm 76 at a predetermined distance therefrom. This chamber 93 terminates at a discharge port 94 that is concentric to the vertical central axis 101 of the valve assembly 70 and has a recessed bore 95 on its upper end into which a screen 96 is positioned.
The screen 96 consists of a disc of mesh material 97 encased in a light frame 98 to make the screen 96 a rigid member.
In FIG. 9, the upper and lower faces 99, or sides, of the diaphragm 76 tapper outward from the center making the outer thickness of the diaphragm considerably thinner than the central part. This taper provides a diaphragm that will have a restorative force sufficient to close abruptly the flow of product at the end of the filling cycle but in which only a minimum of additional force is required to break the seal during the filling cycle.
The nut 81, as previously described, has an inverted conical shape but with arcuately concave side walls 82. The nut 81 is located below the flange 83 and terminates at its lower end in an apex 107 contacting the center of the screen 96, thereby holding the screen in position at all times.
Directional arrows 108 in FIG. 7 show the flow path of the liquid product through the invention when the diaphragm 76 is forced away from its contact with circular corner edge 84 of the face 87.
In operation, during the short time the valve assembly 70 is in closed position, the diaphragm's upper surface 99 in the vicinity of the outer rim 92 is in tight sealing engagement with the adjacent circular corner edge 84 of the plug 75, preventing the downward movement of any residual amount of product into the chamber 93. Concurrently, the screen 96 is effective to hold back all the product that might be in the chamber 93 once the diaphragm 76 has closed off the flow of product from the metering chamber. The screen 96, in other words, holds back all of the residual product below the diaphragm and, in conjunction with the quick-acting diaphragm, serves to eliminate any dripping which might otherwise contaminate the filling station.
During filling, the piston head 21 almost instantaneously acts on the relatively incompressible fluid product to build up the pressure necessary to flex the diaphragm into the open, bell-shaped configuration shown in FIG. 7, thereby permitting the chamber 93 to fill quickly and form a wide, easy flowing stream which emerges from the screen and fills the container rapidly but without any splashing. | A pressure-actuated valve is adapted to the discharge port of a positive displacement machine for filling, sequentially, passing open containers with a liquid product. In response to the sequential pulses of liquid produced at the discharge port, the pressure-actuated valve opens and closes to deliver a predetermined amount of liquid to a waiting container. Even with low viscosity fluids, operation of the valve remains effective, permitting release of fluid during the delivery period yet preventing contaminating drips of fluid from the nozzle during non-delivery periods. Owing to the special valve design, delivery of accurate amounts of liquid and elimination of nozzle drip between container filling cycles are ensured, regardless of slowdown or interruption of machine operation. Contamination of the filling station resulting from product splash is also eliminated despite high speed operation of the machine. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a trailer coupling for motor vehicles with a bar on which a ball is located in the usual manner.
As long as trailer couplings are not used the ball-bar protruding beyond the rear bumber disturbs. For solving this problem trailer couplings are known whose ball-bar may be disassembled. It has been found that the disadvantage of the known trailer couplings is that the disassembly of the ball-bar is physically very demanding.
BRIEF SUMMARY OF THE INVENTION
It is the object of the invention to put forward a trailer coupling which does not have this disadvantage.
The object is solved by the features of patent claim 1 .
Further advantageous formations of the invention are described in the dependent claims 2 to 8 .
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail by way of a preferred embodiment form with reference to the drawings, wherein further advantageous details can be deduced from the drawings. The same parts with regard to their function are provided with the same reference numerals.
The drawings show individually:
FIG. 1 an elevation of the trailer coupling according to the invention, with an axial adjustment into the idle position,
FIG. 2 a lateral view of the trailer coupling according to the invention and according to FIG. 1,
FIG. 3 a lateral view of a ball-bar according to FIG. 1,
FIG. 4 an elevation of a sleeve for receiving the ball-bar according to FIG. 3,
FIG. 5 a lateral view of the sleeve according to FIG. 4,
FIG. 6 a view according to arrow A in FIG. 5,
FIG. 7 a lateral view of an alternative embodiment form with a pivotable ball-bar,
FIG. 8 a section according to line B—B of FIG. 7, through the drive of the ball-bar,
FIG. 9 a lateral view of a further embodiment form with a laterally pivotable coupling bar, and
FIG. 10 a plan view of the embodiment form according to FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 the adjustable trailer coupling is indicated at 1 . It consists essentially of an axially adjustable bar 2 whose outer end carries a ball 3 as well as a guiding sleeve 4 , a motor with planet gears 6 , a spur gear 7 and an adjusting spindle 8 .
The guiding sleeve 4 on both sides carries in each case an assembly flange 9 in which there are incorporated threaded bores 10 . The whole trailer coupling 1 is assembled onto a vehicle in that by way of screws it is fastened onto a suitable bracket of the vehicle. With this screws engage into the threaded bores 10 .
The bar 2 is accomodated by the guiding sleeve 4 . For this purpose the bar 2 comprises a rear guiding surface 11 and a front guiding surface 12 which via a cone 13 blend into a somewhat slimmer bar 2 .
Furthermore in the guiding sleeve 4 an annular inner cone 14 is fastened. Finally in the guiding sleeve 4 there are formed guiding slots 15 .
On the bar 2 in the rear region there is fastened a pin-like connecting rod 16 which engages into the guiding slot 15 . Furthermore in the bar 2 there is incorporated a pocket hole with an inner thread 17 .
The adjusting spindle 8 is screwed into the mentioned inner thread 7 and is rotated by an electrical motor via the spur gear 7 as well as the planet gear 6 . The individual gearwheels of the gear 7 are mounted between lateral plates 19 and 20 . The housing of the planet gear 6 and the guiding sleeve 4 are rigidly connected to the plate 20 . The adjusting spindle 8 is likewise rotatably mounted in the plates 19 and 20 so that it can be rotated by the electrical motor 5 as desired.
If the motor 5 is driven in the corresponding direction, then the adjusting spindle 8 also rotates. At the same time the bar 2 which is arranged as a nut on the adjusting spindle 8 and is secured against rotation by the connecting member 16 is pushed outwards. With this axial movement the bar 2 is guided in the guiding sleeve 4 by the guiding surfaces 11 and 12 . The bar reaches its end position when the outer cone 13 sits rigidly in the annular inner cone 14 .
As long as the guiding slots 15 run in the axial direction, the bar 2 maintains its radial position. After roughly half the adjusting distance the guiding slots 15 blend into a spiral-shaped course. This results in the fact that the bar 2 on extending then correspondingly turns so that the ball 3 in the operating position points vertically upwards. The operating position is shown in FIGS. 1 and 2 by dashed lines.
For a better understanding the essential parts are again individually shown in FIGS. 3 to 6 .
An alternative embodiment form of a trailer coupling is shown in FIG. 7 . With this embodiment form the bar 2 is not axially displaced, but is pivoted about an axis 24 .
For an easier understanding only the bar 2 with its pivoting drive 21 is shown, wherein known additional drive parts such as a gear motor, are not shown.
FIG. 7 shows a pivoting drive 21 with which the bar 2 can be pivoted upwardly about approximately 90° .
The drive however can in a slightly modified form serve for passing through other pivoting angles.
With a correspondingly modified installation location, and an adapted bar 42 for this, a modified pivoting drive 41 may also be applied for a horizontal pivoting of the bar 42 . Such a pivoting drive 41 is shown in the FIGS. 9 and 10.
With the embodiment shown in FIG. 7 the bar 2 however is pivoted vertically upwards. For this purpose it is pivotably mounted between two plates 22 and 23 about the axis 24 on the pintail 25 .
Furthermore the bar 2 comprises a limb 26 whose function can be seen from FIG. 8 .
In FIG. 8 a section corresponding to the marking effected in FIG. 7 is shown. In the region of the limb 26 the bar 2 is thus provided with a slot 27 . Furthermore perpendicular to the plane of the slot there is provided a bearing bore 28 for the pintail 25 , a bearing bore 29 for a pinion shaft 31 as well as a bore with an inner thread 30 for a blocking cone 32 .
As mentioned the pintail 25 is rotatably mounted between two plates 22 and 23 . In the region of the slot 27 of the bar 2 , the pintail 25 comprises a toothing 33 . A gearwheel 34 engages into this toothing 33 , the gearwheel being mounted on the pinion shaft 31 . With the gearwheel 34 there meshes a further gearwheel 35 which is connected to a shaft 36 in a rotatably rigid manner.
On the shaft 36 on both sides of the gearwheel 35 there is each mounted a blocking cone 32 in a rotatably rigid but axially displaceable manner. This blocking cone 32 comprises an outer thread 37 which engages into the inner thread 30 . For the blocking cone 32 a locking opening 38 is provided in the plates 22 and 23 .
In the position shown in FIG. 8 the blocking cone 32 should be retracted in the usual manner into the locking opening 28 . For a better recognition it is shown in a position in which the bar 2 may be pivoted.
The ends of the pinion shaft 31 are guided in arc-shaped slots 39 of the plates 22 and 23 . The remaining bores of the plate 22 shown in FIG. 7 serve for its fastening onto the vehicle or serve the fastening of a further gear with a suitable electrical drive or the connection by way of distance bolts.
The position of the bar 2 represented in FIG. 7 with dashed lines corresponds to its operating position. For pivoting the bar 2 then, a gearwheel 40 rigidly connected to the pintail 25 is driven. Since firstly the blocking cone 32 is retracted into the locking opening 38 of the plate 23 , the bar 2 can still not be pivoted about the axis 24 . Instead of this via the toothing 33 and via the gearwheel 34 the gearwheel 35 is rotated. Since this gearwheel is rigidly connected to the shaft 36 , the shaft 36 drives the blocking cone 32 . Since the outer thread 37 of the blocking cone is engaged with the inner thread 30 , at the same time the blocking cone 32 moves axially inwards until it is completely extended out of the locking opening 38 . As soon as the blocking cone 32 comes to bear on the gearwheel 35 , the gearwheel 35 and the gearwheel 34 which is engaged with it are blocked. By way of this the pintail 25 drives the blocked gearwheel 34 and the pinion shaft 31 , so that the pinion shaft 31 is pivoted about the axis 24 . At the same time the pinion shaft 31 which is mounted in the bearing bore 29 of the bar 2 then drives this bar so that the bar 2 is pivoted. This pivoting movement finishes as soon as the pinion shaft 31 reaches the end of the slot 39 .
For the purpose of clarity it must be mentioned that in FIG. 8 the left blocking cone is not shown.
For the electrical drive it is provided for this to be switched off as soon as the laod exceeds a previously set limiting value. In this way damages are avoided, in the case that on moving the bar 2 foreign bodies should inhibit the further operation. So that the adjustment cannot be initiated during the journey of the vehicle it is furthermore provided for the trailer coupling to only be able to be operated outside the compartment of the vehicle. It is particularly advantageous when the operating means, for example a switch, is arranged in the boot of the vehicle.
In this manner there is created a vehicle coupling which is easily and comfortably brought into a position in which it no longer disturbs. | A trailer coupling for motor vehicles has a bar, a ball provided on the bar, the bar being automatically adjustable between an idle position and an operating position, and an adjusting drive including an electric motor which automatically adjust the bar between the idle position and the operating position. | 1 |
CLAIM FOR PRIORITY
[0001] This application is based on U.S. Provisional Application No. 61/459,978 of the same title filed Dec. 22, 2010, the priority of which is hereby claimed and the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates, in part, to a process for the selective removal of acetylenic impurities and carbonyl impurities from gaseous hydrocarbon streams.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to a process for the selective removal of acetylenic and carbonyl impurities, especially acetylenic impurities, from gaseous streams without significantly affecting the recovery of the desired hydrocarbons. The process of this invention is particularly useful for the removal of acetylenic impurities from gaseous streams of organic compounds.
[0004] The terms “acetylenes” or “acetylenic impurities” are used interchangeably herein to denote acetylene, vinyl acetylene, methyl acetylene, ethyl acetylene and the like. Such compounds are often found as impurities in various organic product streams. For example, the oxidative or non-oxidative dehydrogenation of C4-C8 hydrocarbons having at least one
[0000]
[0005] grouping to produce the corresponding ethylenically unsaturated hydrocarbons produces small amounts of acetylenes. Similarly, in the production of olefinic hydrocarbons by the cracking of hydrocarbon feed streams, certain quantities of acetylenes are produced. Some ethylene recovery processes, for example, the cuprous salt method, necessitate that the acetylenes be first removed, since acetylene reacts with the cuprous ions to form an explosive compound. Furthermore, ethylene utilized for the purpose of polymerization requires an almost total removal of acetylenes.
[0006] Thus, a great effort has been expended to develop methods for removing acetylenes from organic streams, particularly C2-C8 paraffinic and olefinic hydrocarbons. Two approaches have been employed (1) physical, involving distillations, extractions, extractive distillation and various combinations of physical processes and (2) catalytic. In the former process, if the concentration of acetylenic impurities is high, it may reach dangerous levels where detonation can occur. Thus, catalytic approaches have generally been preferred.
[0007] Some catalytic approaches in the art are described U.S. Pat. Nos. 3,476,824; 3,728,412; 4,009,126; 4,075,256; 4,083,887; 4,513,159; 4,658,080; and United States Patent Application Publication No. US 2004/0122275 which disclosures are incorporated herein in their entirety. Some of the catalytic processes involve hydrogenating the acetylenic impurities back to alkenes and alkanes. However, this approach could result in some loss of the desired alkenes and alkadienes.
[0008] Thus, it would be preferable to find a process for selectively removing most of the acetylenic impurities (e.g., at least 80%, preferably at least 95%) from a gaseous stream without significantly affecting the recovery of the monoolefins and diolefins, particularly the desired diolefins. It would be preferable to recover at least 95% of the desired diolefins in the process.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to processes for selectively removing acetylenic impurities in a gaseous stream. The gaseous stream would contain other organic compounds, particularly C1 to C9 unsaturated hydrocarbon monoolefins and diolefins which would be the principal or desired products of the stream. Preferred hydrocarbon monoolefins and diolefins would have 2 to 8 carbon atoms and more preferably 4 to 6 or 8 carbon atoms. The instant process removes the acetylenic impurities to less than 10 ppm and still more preferably to less than 5 ppm. The process is especially suitable for removing the acetylenic impurities and recovering most of the diolefins. The inventive process is similarly effective for removing oxygenates such as aldehydes which may be present.
[0010] Briefly, the process comprises contacting an input stream of organic compounds containing acetylenic impurities in the vapor phase, along with steam, and in some embodiments in the substantial absence of added oxygen and hydrogen in the input stream, with a catalyst for removing most of said acetylenic impurities from said input stream, said catalyst most preferably comprising as the major cation elements by weight Ba, Ni, Na and Fe. Zinc catalyst components tend to be expensive and/or difficult to process and their absence is accordingly highly desirable.
[0011] In one embodiment of the invention, a zinc-free catalyst is used to remove impurities from an input stream having one or more hydrocarbons, acetylenic impurities and steam selected from streams (a), (b), (c), (d), or (e), wherein stream (a) comprises ethylene in at least 75 mol % based on the hydrocarbon, acetylenic impurities and steam content of the stream; stream (b) comprises propylene in at least 75 mol % based on the hydrocarbon, acetylenic impurities and steam content of the stream; input stream (c) comprises styrene in at least 75 mol % based on the hydrocarbon, acetylenic impurities and steam content of the stream; input stream (d) comprises isoprene in at least 75 mol % based on the hydrocarbon, acetylenic impurities and steam content of the stream; and stream (e) comprises less than 50 mol % C4 hydrocarbons based on the hydrocarbon content of the input stream.
[0012] In another embodiment, the present invention is directed to a vapor phase process for the selective removal of at least 95 mole % of acetylenic impurities from an input gaseous stream wherein said input stream comprises C1 to C9 unsaturated hydrocarbon monoolefins and diolefins, acetylenic impurities and steam, with no added hydrogen or oxygen, wherein the process comprises contacting said input stream in the vapor phase at a temperature in the range of about 480° F. to about 1650° F. with a solid zinc-free catalyst, said catalyst being preferably derived from oxides, carbonates and/or hydroxides of Ba, Ni, Na and Fe, wherein said Ba is present in about 0.25-40 wt % on dry basis of said catalyst, Ni is present in about 0.25-20 wt % on dry basis of said catalyst, Na is present in about 0.25-40 wt % on dry basis of said catalyst, with the remainder being Fe, and recovering an output stream wherein said output stream retains at least 95 mole % of said C1 to C9 unsaturated hydrocarbon diolefins but lacks at least 80 mole % of said acetylenic impurities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention is described in connection with by the attached Figures, wherein FIG. 1 is a gas chromatograph of crude 1,3-butadiene hydrocarbon stream containing acetylenic impurities (peaks 12, 13 and 14) to be purified; and FIG. 2 is a gas chromatograph of a refinery gas stream containing mixtures of various C2-C6 hydrocarbons and acetylenic impurities (peak 9) to be purified.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The invention is described in detail below with reference to the drawings and examples. Such discussion is for purposes of illustration only. Modifications within the spirit and scope of the present invention, set forth in the appended claims, will be readily apparent to one of skill in the art. Terminology used throughout the specification and claims herein is given its ordinary meaning except as more specifically defined; for example, acetylene removal is calculated as the difference between the acetylene content of the input stream minus the acetylene content of the output stream.
[0015] Ba, Ni, Na and Fe content of the catalyst is based on the relative metal oxide content of catalytic metal oxides in the catalyst for convenience as is commonly done in the art. See U.S. Pat. No. 4,695,661, the disclosure of which is incorporated herein by reference. In order to determine content of these metals, the catalyst is placed in an oven overnight at 480° C. in air and the catalytic metal oxide content is thereafter measured by x-ray diffraction and infra red spectroscopy or other suitable technique(s). A catalyst analyzed with 10% barium oxide based on the catalytic metal oxide content (i.e oxides of Ba, Na, Ni and Fe in the examples) is referred to as a catalyst containing 10% barium on a dry basis of said catalyst herein.
[0016] The acetylenic impurities are a serious contaminant in the unsaturated hydrocarbon product stream and must be essentially substantially completely removed in order to have a product of suitable purity, i.e., a product having on the order of not more than a few parts per million acetylenic impurities. The essentially substantially complete removal of the acetylenic compounds is quite difficult for several reasons. Principally, the acetylenic compounds constitute only a very minor percentage of the gaseous stream to be purified. Normally, acetylenic impurities will constitute less than 5.0 mol percent of the gaseous stream. Generally the gaseous stream will contain at least about 0.5-2.0 mol percent acetylenic impurities based on the other organic compounds present such as the ethylenically unsaturated hydrocarbons. Their low concentration in the stream makes acetylenes quite difficult to remove. Moreover, azeotropes may form between the acetylenic impurities and the various other hydrocarbons present.
[0017] The organic compounds which can be treated according to the present process generally have 1 to 9 carbon atoms. The major portion of the stream can be saturated and/or unsaturated (excluding acetylenic unsaturates) compounds and may comprise straight chain and/or branched compounds, similarly the desired compounds may be cyclic, acyclic or aromatic or mixtures of the foregoing. An illustrative, typical hydrocarbon feed in the input stream may contain, for example, mixed butenes (isobutene, 1-butene, cis-2-butene, trans-2-butene, 1,3-butadiene etc.) with acetylenes (such as, for example, methyl acetylene, ethyl acetylene, vinyl acetylene and the like), any butanes, mixed C5 hydrocarbons or other hydrocarbons. An example hydrocarbon stream would be the crude mixed butane/butadiene stream from ethylene cracker or the mid-process stream in butane/butadiene purification.
[0018] A preferred group of compounds are hydrocarbons having 1 to 9 carbon atoms, typically monoolefins and diolefins. A more preferred group of compounds are hydrocarbons having 2 to 8 carbon atoms, typically monoolefins and diolefins. A still more preferred group of compounds are hydrocarbons having 4 to 8 carbon atoms, typically monoolefins and diolefins. The process is a purification and hence the acetylenic impurities are present in only minor amounts in comparison to the other organic compounds in the stream.
[0019] The preferred catalyst used in the inventive process typically contains the atoms of Ba, Ni, Na and Fe. However, no zinc or zinc compounds are present. The Ba, Ni, Na and Fe atoms may be present in the form of the metal compounds such as oxides, salts or hydroxides. Many of these metals, oxides, salts and hydroxides may change during the preparation of the catalyst, during heating in a reactor prior to use in the process of this invention, or are converted to another form under the described reaction conditions, but such materials still function as an effective catalyst in the defined process to impart the removal or destruction of acetylenic impurities. However, some metal compounds are more effective than other compounds of the same metal and, therefore, the compound giving the most effective results can be chosen. Preferably, catalysts, which are solid under the conditions of acetylene removal, will be used. Preferably, the compound will exhibit some basicity, e.g., as in the case of oxides, carbonates, or hydroxides.
[0020] The amount of barium or other alkaline earth element employed is about 0.25-40 wt % on dry basis based on total catalytic metal oxide weight (excluding any support or diluents), preferably about 1-20 wt % on dry basis of said catalyst, and more preferably about 5 to 15 or 5 to 10 weight percent. The amount of nickel employed is about 0.25-20 wt % on dry basis based on total catalytic metal oxide weight (excluding any support), preferably about 1-15 or 1-10 wt % on dry basis of said catalyst, and more preferably about 7 to 15 weight percent. The amount of sodium or other alkali metal employed is about 0.25-40 wt % on dry basis based on total catalytic metal oxide catalyst weight (excluding any support), preferably about 0.5-30 wt % on dry basis of said catalyst, and more preferably 10 to 25 or 10 to 15 weight percent. The remaining amount of catalytic metal oxide in the catalyst is typically iron. In a typical experiment, the amount of iron is in the range of about 30-75 or 30-55 weight %, preferably 30-65 or 30-50 weight %, and more preferably about 35-45 weight %.
[0021] In an illustrative preparation of the catalyst, yellow iron oxide (Fe 2 O 3 .H 2 O, dry powder), barium carbonate (BaCO 3 , dry powder), basic nickel carbonate (also known as Nickel(II) carbonate hydroxide hydrate, dry powder), sodium hydroxide (NaOH, as aqueous solution) are used. The dry ingredients are blended to give a uniform powder. Water is added and mixed well. The mix is dried to remove the water. Exposure to air is avoided after drying. The catalyst is reduced in the reactor before interacting with the incoming stream. Some suitable reduction methods are reduction at high temperature with hydrogen, or natural gas or other suitable reducing agents. Such suitable methods are described, for example, in the afore-mentioned U.S. Pat. No. 4,513,159.
[0022] The catalyst is preferably in solid form. If desired, it can be extruded and dried into a desired shape. The catalyst may be used as such or may be coated or otherwise supported on non-reactive, inert catalyst carriers (“supports”). Catalyst carriers are known in the art and include such compounds as alumina, silica, silicon carbide, pumice, glass and so forth. Diluents may also be incorporated into the catalyst so long as the diluent does not prevent the catalyst from functioning. Preferably the carrier should be low surface and low acidity. When carriers are used, the amount of catalyst on the carrier will generally be between about 5 and 75 weight percent of the total weight of the active catalytic material plus carrier. The present process is not an oxidative dehydrogenation since the input stream does not contain substantial amounts of oxygen. The input additionally lacks substantial amounts of added hydrogen. The molar ratio of oxygen content to hydrocarbon content in the input stream is generally less than 0.01, preferably less than 0.005 and more preferably less than 0.0025. While not intending to be limited to any mechanism, it is believed that the present process is a carbonization of the acetylenes. The output stream contains hydrogen presumably the hydrogen removed from the acetylenes which then become carbonized, as well as that produced by water gas shift between steam and said carbonized product:
[0000] (e.g. H2O+C→H2+CO(ΔH=+131 kJ/mol)) CO(g)+H2O(v)→CO2(g)+H2(g) (ΔH =−41.1 kJ/mol).
[0023] In an illustrative description of the present process, the input hydrocarbon mix containing the acetylenic impurities is vaporized and mixed with steam at a desired steam/hydrocarbon ratio. The steam/hydrocarbon ratios mol/mol are generally about 1-25 respectively, preferably being about 2 to 15 steam/HC, more preferably being about 3 to 8, and still more preferably about 3-5 steam/HC. The mix of hydrocarbon and steam (“the input stream”) is run over a bed of the catalyst as described above at a targeted liquid hourly space velocity (“LHSV”) based solely on the hydrocarbon feed. The targeted LHSV may generally be in the range of 1-8, preferably 2-6 and more preferably 3-5. The temperature of the bed is controlled to be in the range about 480-1650° F. generally, about 600-1,400° F. preferably, about 900-1200° F. more preferably and about 900-1000° F. typically, by adjusting the steam temperature and/or providing external heat to the system. The pressure of the bed is controlled to be about 0-300 psia generally, about 2-200 psia preferably, about 10-50 psia more preferably and about 14-16 psia typically, by controlling off-gas pressure. The exit or effluent gas is cooled to condense water away from the hydrocarbons. The recovered hydrocarbon mix is sent for further purification to separate the hydrocarbons from the CO, CO 2 and hydrogen as needed.
[0024] After the catalyst has been used for a period of time it may be regenerated such as by controlled oxidation with air and/or with steam in the absence of hydrocarbon.
[0025] The following examples are only illustrative and are not intended to limit the invention. All percentages are by weight unless expressed otherwise.
EXAMPLE 1
[0026] Preparation of Catalyst on Support: An acetylene removal catalyst was prepared as follows: 26.81 grams of Fe 2 O 3 .H 2 O, 3.82 grams of BaCO 3 , 7.27 gms of basic NiCO 3 were placed in a blender and dry mixed together to form a uniform powder. 8.38 grams of NaOH in 320 grams of water was added and the mix was made into a very thin yellow liquid. The liquid was poured into a 2 liter round bottomed glass flask containing 0.24 inch of 316 stainless steel packing. About 30 ml of additional water was used to rinse the blender and lid into the round bottomed flask. The flask was placed on a rotovap and water was removed in vacuo at about 50-80° C. for about 0.5-2 hours or until the support appeared well coated and dry. The flask was removed from the rotovap and placed in an oven at about 110° C. overnight to dry. The coated support looked yellow to yellowish brown in color and it was kept away from air until use.
[0027] Prior to use for acetylene removal from the input stream of hydrocarbons, the catalyst is preferably reduced. The reduction could be carried out in a number of methods. For example, a flow of hydrogen through the catalyst for from 5 minutes to several hours, e.g., 5 hours at temperatures of about 500° F. to about 1600° F. was found suitable. Generally, the temperature of about 900-1100° F. was found adequate. Other reducing compounds such as n-butane could also be used to reduce the catalyst. The reduction seemed beneficial to the acetylenes removal.
EXAMPLE 2
[0028] Acetylene Removal from a Hydrocarbon Mix: The equipment used was similar to the one described for acetylene removal in the afore-mentioned U.S. Pat. No. 4,453,159. The reactor was a 24 inch long, 1 inch I.D. stainless steel tube inserted in a 3100 watt furnace having three separate temperature control elements. The upper 8 inches serve as a steam super heater. The hydrocarbon feed was injected into the super heated steam prior to the steam entering a catalyst bed of about 10 inches length with inert support on top and bottom of the bed to fill the reactor. The effluent was sampled after cooling the outlet stream and condensing the water. Analyses were by gas chromatographic methods.
[0029] In typical runs, the hydrocarbon mix was vaporized and mixed with steam at a desired steam/hydrocarbon ratio. This input stream was run over the catalyst bed at a targeted LHSV based solely on the hydrocarbon feed composition. Temperature of the bed was controlled by adjusting the steam temperature and/or providing external heat to the system. The exit gas was cooled to condense water away from the hydrocarbons and analyzed. A typical run that was carried out on an input hydrocarbon stream containing butadienes to selectively remove the acetylenes and recover most of the butadienes is shown in Table 1:
[0000]
TABLE 1
In
Out
Remarks
Temp.
1030° F.
LHSV (L/L/hr)
2
Steam/hydrocarbon
4:1
ratio (mol/mol)
Butadiene content,
52.7
52.4
Recovery 99.4%
mole %**
Acetylene content*
1.40
0.01
Acetylene removal:
mole %**
99.6%
Carbon oxides
0.00
7.02
(mol %)***
Hydrogen
0.00
16.15
(mol %)***
*Sum of methyl acetylene, ethyl acetylene and vinyl acetylene
**Butadiene content and acetylene content are based on hydrocarbon content only.
***Carbon oxides content and hydrogen content are given as percentage in the outlet sample.
[0030] Even though the foregoing Example illustrates the removal of acetylenes from a 1,3-butadiene input stream, the present invention is suitable for removal of acetylenic impurities from various other hydrocarbon streams too such as, for example, C2 gas streams (ethylene), C3 gas streams (propylene), C5 gas streams (isoprene), C6 gas streams (styrene) and the like. For example, gas streams containing at least 75 mol % C2 hydrocarbons, or at least 75 mol % C3 hydrocarbons, or at least 75 mol % C5 hydrocarbons or at least 75 mole % C6 hydrocarbons can be purified of acetylenes by methods similar to that as described above. It is further contemplated that the removal of acetylenes from such C2, C3, C5 or C6 hydrocarbon streams can be carried out with or without having a substantial absence of added oxygen and substantial absence of added hydrogen in the input stream. For example, an input stream containing a C2 (or C3 or C5 or C6) hydrocarbon mix and steam can be passed over a catalyst bed as described in the present invention under the inventive conditions and freed of at least 80 mol % of acetylenic impurities, irrespective of whether there is added oxygen or not, or added hydrogen or not, in the input stream. Generally, such embodiments also include cases where the gas is other than a stream consisting primarily of C4 hydrocarbons as shown in FIG. 1 . For example, the invention may be used to purify a refining gas stream having the composition shown in FIG. 2 with or without added oxygen or hydrogen. Typically, the invention is used to purify hydrocarbon streams being less than 50 mol % C4 hydrocarbons with or without added oxygen and such streams may have less than 20 mol % or less than 10 mol % C4 hydrocarbons based on the hydrocarbon content. Such modifications are also to be considered as part of the present invention.
[0031] As can be seen clearly, the instant invention affords a novel process to selectively remove acetylenic impurities from a hydrocarbon mix without detrimentally affecting the desired diolefins.
[0032] There is provided in one aspect of the invention a vapor phase process for selective removal of at least 80 mole % of acetylenic impurities from an input gaseous stream wherein said input stream comprises C1 to C9 unsaturated hydrocarbon monoolefins and diolefins, acetylenic impurities and steam with or without substantial amounts of added hydrogen or oxygen, wherein said process comprises contacting said input stream in the vapor phase at a temperature in the range of about 250° C. (480° F.) to about 900° C. (1650° F.) with a solid zinc-free catalyst, said catalyst derived from and preferably including oxides, carbonates and/or hydroxides of Ba, Ni, Na and Fe, wherein said Ba is present in about 0.25-40 wt % on dry basis of said catalyst, Ni is present in about 0.25-20 wt % on dry basis of said catalyst, Na is present in about 0.25-40 wt % on dry basis of said catalyst, with the remainder being Fe, and recovering an output stream. The output stream retains at least 95 mole % of said C1 to C9 unsaturated hydrocarbon monoolefins and diolefins but lacks at least 80 mole % of said acetylenic impurities. Preferably, the process selectively removes at least 95 mol % of said acetylenic impurities. The selectively removed acetylenic impurities may include vinyl acetylene and the input stream optionally comprises C2 to C8 hydrocarbon compounds, acetylenic impurities and steam with no added hydrogen or oxygen. In some cases, the input stream contains less than 50% C4 hydrocarbons and in others, the input stream contains less than 25% C4 hydrocarbons, such as less than 20% C4 hydrocarbons. The process may be operated at temperature ranges from about 315° C. (600° F.) to about 760° C. (1400° F.) such as at temperature ranges from about 480° C. (900° F.) to about 650° C. (1200° F.) and at pressures of about 0-2.1 MPa (0-300 psia).
[0033] Ba may be present in about 1-20 wt % on dry basis of said catalyst, Ni may be present in about 1-10 wt % on dry basis of said catalyst, Na may be present in about 0.5-30 wt % on dry basis of said catalyst, with the remainder being Fe. A preferred process is where Ba is present in about 5-8 wt % on dry basis of said catalyst, Ni is present in about 7-9 wt % on dry basis of said catalyst, Na is present in about 10-14 wt % on dry basis of said catalyst, with the remainder being Fe. The catalyst may be prepared from barium carbonate, nickel carbonate, sodium hydroxide and iron oxide.
[0034] In some cases, the input stream contains about 1-2 mole % acetylenic impurities and said output stream contains less than 0.02 mole % acetylenic impurities and the output stream retains more than about 98 mole % of said C1 to C9 unsaturated hydrocarbon monoolefins and diolefins. Optionally, the output stream is cooled to remove water and additionally the process includes the step of regenerating the catalyst after use. Typically, said regeneration comprises controlled oxidation with air or steam in the absence of hydrocarbon.
[0035] In some embodiments, the molar ratio of oxygen content to hydrocarbon content in the input stream is less than 0.01.
[0036] In another aspect of the invention, there is provided a vapor phase process for selective removal of at least 80 mole % of acetylenic impurities from an input gaseous stream wherein said input stream comprises ethylene in at least 75 mol % based on the hydrocarbon content of the stream, acetylenic impurities and steam, further wherein said process comprises contacting said input stream in the vapor phase at a temperature in the range of about 250° C. (480° F.) to about 900° C. (1650° F.) with a solid zinc-free catalyst, said catalyst derived from and preferably including oxides, carbonates and/or hydroxides of Ba, Ni, Na and Fe, wherein said Ba is present in about 0.25-40 wt % on dry basis of said catalyst, Ni is present in about 0.25-20 wt % on dry basis of said catalyst, Na is present in about 0.25-40 wt % on dry basis of said catalyst, with the remainder being Fe, and recovering an output stream wherein said output stream retains at least 95 mole % of said ethylene but lacks at least 80 mole % of said acetylenic impurities.
[0037] In still another aspect of the invention, there is provided a vapor phase process for selective removal of at least 80 mole % of acetylenic impurities from an input gaseous stream wherein said input stream comprises propylene in at least 75 mol % based on the hydrocarbon content of the stream, acetylenic impurities and steam, further wherein said process comprises contacting said input stream in the vapor phase at a temperature in the range of about 250° C. (480° F.) to about 900° C. (1650° F.) with a solid zinc-free catalyst, said catalyst derived from and preferably including oxides, carbonates and/or hydroxides of Ba, Ni, Na and Fe, wherein said Ba is present in about 0.25-40 wt % on dry basis of said catalyst, Ni is present in about 0.25-20 wt % on dry basis of said catalyst, Na is present in about 0.25-40 wt % on dry basis of said catalyst, with the remainder being Fe, and recovering an output stream wherein said output stream retains at least 95 mole % of said propylene but lacks at least 80 mole % of said acetylenic impurities.
[0038] Yet another aspect of the invention provides a vapor phase process for selective removal of at least 80 mole % of acetylenic impurities from an input gaseous stream wherein said input stream comprises isoprene in at least 75 mol % based on the hydrocarbon content of the stream, acetylenic impurities and steam, further wherein said process comprises contacting said input stream in the vapor phase at a temperature in the range of about 250° C. (480° F.) to about 900° C. (1650° F.) with a solid zinc-free catalyst, said catalyst derived from and preferably including oxides, carbonates and/or hydroxides of Ba, Ni, Na and Fe, wherein said Ba is present in about 0.25-40 wt % on dry basis of said catalyst, Ni is present in about 0.25-20 wt % on dry basis of said catalyst, Na is present in about 0.25-40 wt % on dry basis of said catalyst, with the remainder being Fe, and recovering an output stream wherein said output stream retains at least 95 mole % of said isoprene but lacks at least 80 mole % of said acetylenic impurities.
[0039] Still yet another aspect of the invention provides a vapor phase process for selective removal of at least 80 mole % of acetylenic impurities from an input gaseous stream wherein said input stream comprises styrene in at least 75 mol % based on the hydrocarbon content of the stream, acetylenic impurities and steam, further wherein said process comprises contacting said input stream in the vapor phase at a temperature in the range of about 250° C. (480° F.) to about 900° C. (1650° F.) with a solid zinc-free catalyst, said catalyst derived from and preferably including oxides, carbonates and/or hydroxides of Ba, Ni, Na and Fe, wherein said Ba is present in about 0.25-40 wt % on dry basis of said catalyst, Ni is present in about 0.25-20 wt % on dry basis of said catalyst, Na is present in about 0.25-40 wt % on dry basis of said catalyst, with the remainder being Fe, and recovering an output stream wherein said output stream retains at least 95 mole % of said styrene but lacks at least 80 mole % of said acetylenic impurities.
[0040] There is also provided in another aspect of the invention, a vapor phase process for selective removal of acetylenic impurities from an input gaseous stream wherein said input stream comprises acetylenic impurities, steam, and hydrocarbons, with the proviso that the stream comprises less than 50 mol % C4 hydrocarbons based on the hydrocarbon content of the stream, further wherein said process comprises contacting said input stream in the vapor phase at a temperature in the range of about 250° C. (480° F.) to about 900° C. (1650° F.) with a solid zinc-free catalyst, said catalyst derived from and preferably including oxides, carbonates and/or hydroxides of Ba, Ni, Na and Fe, wherein said Ba is present in about 0.25-40 wt % on dry basis of said catalyst, Ni is present in about 0.25-20 wt % on dry basis of said catalyst, Na is present in about 0.25-40 wt % on dry basis of said catalyst, with the remainder being Fe, and recovering an output stream wherein said output stream retains at least 95 mole % of said ethylene but lacks at least 80 mole % of said acetylenic impurities.
[0041] The processes of the invention may be carried out wherein the process selectively removes at least 95 mol % of said acetylenic impurities and the selectively removed acetylenic impurities are vinyl acetylenes; optionally wherein said input stream contains less than 25% C4 hydrocarbons, such as wherein said input stream contains less than 20% C4 hydrocarbons.
[0042] In the various embodiments of the invention, one preferred catalyst is a catalyst comprising Ni, Fe, an alkali metal such as sodium and optionally an alkaline earth element such as Ba wherein Ni is present in an amount of 0.25-20 wt % on a dry basis of said catalyst and Fe is present in an amount of 30-75% on a dry basis of said catalyst. Such a catalyst may be made with or without zinc.
[0043] In the various embodiments of the invention, another preferred catalyst is a solid zinc-free catalyst, said catalyst comprising Ba, Ni, Na and Fe, wherein said Ba is present in an amount of 0.25-40 wt % on a dry basis of said catalyst, Ni present in an amount of 0.25-20 wt % on a dry basis of said catalyst, Na present in an amount of 0.25-40 wt % on a dry basis of said catalyst, and Fe is present in an amount of 30-75% on a dry basis of said catalyst.
[0044] While the invention has been described in detail, modifications within the spirit and scope of the invention will be readily apparent to those of skill in the art. In view of the foregoing discussion, relevant knowledge in the art and references discussed above in connection with the Background of the Invention, the disclosures of which are all incorporated herein by reference, further description is deemed unnecessary. In addition, it should be understood that aspects of the invention and portions of various embodiments may be combined or interchanged either in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention. | The present discloses a process and catalyst therefor to selectively remove acetylenes from gaseous streams in the vapor phase. The process is particularly suitable for high yield recovery of olefinic hydrocarbons from gaseous streams in refinery processes. | 8 |
This application is a continuation of copending application(s) application No. 09/185,198 filed Nov. 3, 1998, now U.S. Pat. No. 6,044,579, which is a continuation-in-part of application Ser. No. 08/536,998, filed on Sep. 29, 1995, now U.S. Pat. No. 5,829,174, which is a continuation-in-part of application Ser. No. 08/225,215 filed Apr. 8, 1994, and which is now abandoned, which is a continuation-in-part of application Ser. No. 08/053,060, filed Apr. 26, 1993, and which is now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of snow-plows and specifically to articulated snow plows. Generally the snow plow system disclosed herein is intended for use on vehicles like trucks, tractors, skid loaders, pick up trucks, sports utility vehicles, etcetera. However, the snow plow system disclosed herein, or at least some aspects of the snow plow system disclosed herein, is also viewed as having application on all types of snow removal vehicles.
Plows with blades that hinge have a number of advantages over plows with straight nonpivotable blades. A lightweight vehicle, carrying a plow cannot easily push deep, particularly hard, or heavy snow with a straight blade. A centrally hinged plow blade or moldboard (sometimes called an apex type plow because the hinge is at the apex of the V formed when the arms or wings of the plow are in a swept back position) allows the operator of the vehicle a greater mechanical advantage since a plow moldboard, with its wings in the swept back V shaped position, will act like a wedge into the snow. Each wing of the plow moldboard acting like an inclined plane depositing the snow to either side of the vehicle. A plow with a straight blade or moldboard also has difficulty in pushing a mound of snow to an out of the way location. Snow will spill out the sides of a plow with a straight moldboard while a hinged plow that can be articulated can have its wings or arms swept forward to form a V-shaped cup like area between the moveable arms of the moldboard. This swept forward position allows for better containment of the snow so that the snow may be moved out of the way without significant spillage.
Unfortunately, despite the many advantages that hinged plows have there are also disadvantages. For example, when the arms of the plow are in the swept forward position the volume of snow that can be moved is somewhat reduced. Additionally, the single center hinge of hinged snow plows can undergo tremendous stress during plowing, e.g., hitting curbs, rocks, or other objects, and thus the single hinge has a tendency to bend or even break after repeated encounters with such objects. Further, many such plows have very complicated designs which make them difficult or expensive to repair.
Additionally, hinged plows are generally not able to trip effectively when they are in the swept back or swept forward positions. This means that hinged plows have difficulty tipping or tilting in response to encountering a solid object like a curb, an elevated portion of the road bed, a manhole cover, etc. This can lead to jarring impacts which are not desirable and which may adversely affect both the structural integrity of the vehicle and the plow. To attempt to compensate for this problem hinged plows are usually provided with extra mass to prevent damage.
However, additional weight or mass can adversely affect the fuel economy, the handling, and/or the structural integrity of the vehicle to which the plow is mounted and does not make the hinged plow trip in a more effective manner.
It is an object of the present invention to produce an articulated plow system having a center section with at least two or a plurality of pivot points (hinge points) instead one pivot point. The system disclosed herein will thus have a moldboard which can articulate. This means that the moldboard will have a plurality of joints or hinge areas about which portions of the moldboard can pivot.
It is a further object of the present invention to provide a pivot between the main frame and the central section of the blade assembly pivot to allow a few degrees of motion about a horizontal axis. The object is to provide a limited amount of float to permit the blade assembly to follow ground contours and allow for some variations in the mounting height of the vehicle mounting points.
It is a general goal of the present invention to produce an articulated plow system, a plow system having at least two or a plurality of joints, having features which overcome the above noted problems and at the same time provide a snow plow having the advantages of a hinged plow and a regular straight plow.
Further, hinged plows, as previously noted, typically have a point, the apex, where the hinge is located. The apex does not have a wearstrip in front of it to contact snow when plowing. Consequently, when a hinged plow is in the position or the swept back position this results in some snow being missed and a trail of unplowed snow being left behind the vehicle. This is not desirable because it requires that the driver make another sweep of the area just plowed to remove the trail of snow left. This wastes both the time and energy of the driver and the vehicle.
Thus, it is a further object of the present invention to provide a center section which can allow for the installation of a center wearstrip in a such a way that the center and wing wearstrips can overlap. Additionally, it is an object of this invention that the center strip be wide enough to accommodate such overlapping but also be narrow enough to allow for free flow of material across the wearstrip and moldboard surface when the blade assembly is angled fully to the right or to the left.
Further, it is an object of the present invention to use a center wearstrip that sufficiently angled with respect to the road or surface to be plowed so that a wedge or chisel affect to provide additional mechanical advantage to break up hard packed snow.
It is a further object of the present invention to include trip springs and pivots mounted to the center section independent of the main frame to allow for float between the main frame and the blade assembly section. Additionally, it is an object of the present invention to provide a center section having a width substantially greater than the single hinge width of apex type plows to provide more stability to the articulated plow system disclosed herein, greater resistance to side loading, and more durability. Further, by increasing the size of the center section more space is provided on the plow body itself for the tripping structure without any compromise to the structural integrity of the plow or its ability to pivot as desired.
It is a further objective of the present invention to permit blade tripping when the articulated plow disclosed herein is in the scoop position; with the wings of the plow swept forward.
It is a further object of the present invention to produce a plow system that may also be used on vehicles that are not well suited to heavy plows or to be used on vehicles where fuel economy is a consideration. Accordingly, the articulated plow blade of the present invention is designed so that it may be lighter in weight than prior art apex type plows.
It is a further object of the present invention to have a self-contained power unit and means of attaching the power unit mounted on the articulated plow and not the vehicle. This has the advantage of requiring less modification to the vehicle upon which the plow will be used. This will also aid in maintaining the center of gravity of the vehicle to help make the vehicle more stable since the majority of the weight added to the vehicle will be as part of the articulated plow located in front of the vehicle generally below the passenger compartment or cab. This allows the weight of the power unit to become an effective weight at the wearstrip rather than being fixed weight at the vehicle which is not desirable.
It is a further object of the present invention to address the problem of excess, performance reducing, weight on hinged snow plows. The present invention includes a reactive controlled pressure system that places a controlled predetermined pressure upon the moldboard of the plow system so that a portion of the weight of the vehicle to which the plow system is attached is actually transferred to the bottom edge of the plow moldboard and the plow moldboard acts as a moldboard weighing 2 to 3 times its actual weight. This allows the articulated plow blade of the present invention to be lighter in weight but to be as effective or even more effective in plowing as a hinged plow system.
It is a further objective of the present invention to provide the flexibility of having, in effect, both a light weight articulated plow (which is advantageous for certain conditions such as plowing light snow on a gravel driveway) and a heavy weight plow (which is advantageous for plowing drifted and hard packed snow and for scraping hard surfaces). This flexibility is obtained by having a reactive controlled pressure system which can be activated and de-activated by means of a simple electric control switch. The controlled pressure mechanism maintains a pressure within a certain predetermined low pressure and high pressure limit with a predetermined nominal pressure within these limits.
It is a further objective of the present invention to provide an articulated plow having a bell crank lift arm combination for lifting the articulated plow.
It is a further object of the present invention to have only a small mounting subframe located beneath the front bumper of the vehicle which is attached to the vehicle frame. All other components of the snow plow system are mounted to this mounting subframe so that they can be easily and quickly removed from the vehicle. Consequently, there is no substantial amount of mounting equipment covering the front end of the vehicle and little added weight permanently attached to the vehicle.
It is a further objective of the present invention to include a quick connecting/disconnecting structure to make it very easy to attach or disengage the snow-plow system from the vehicle. This saves the operator of the vehicle both time and effort when installing and removing the snow plow system.
Further, the present invention addresses the problem of lights mounted to vehicles for plowing. Typically an additional set of headlights and parking lights are mounted to the front end of a vehicle for plowing. This is because the regular headlights and parking lights of the vehicle are usually hidden behind the plow moldboard and thus are obstructed by the plow moldboard especially in the raised position. As such, the lights are rendered ineffective. Consequently it has been the case that an additional set of lights are mounted either upon the hood or up on the front grill of the vehicle so that they project over the front edge of the plow moldboard. The problem with this procedure is that these lights and their housings in and of themselves create obstructions in the driver's field of vision due to the fact that they are mounted on the vehicle. To overcome this problem it has been attempted in the prior art, in straight or traditional plows, to move the lighting system to a position off the vehicle and onto the plow structure itself. The device of the present invention moves these lights off of the vehicle and positions them so that they shine over the top edge of the moldboard, while presenting a minimal obstruction to the field of vision of the driver or operator of the vehicle. Since the additional lights are mounted on the plow and not on the vehicle they are removed when the snow-plow is removed. This eliminates having a second set of lights permanently mounted on the vehicle. Further, it is an objective of the present invention to allow these lights to be mounted to a fixed position or mounted to a telescoping mount so that their position may be independently adjusted.
It is a further object of the present invention to provide a simplified structure for moldboard attachment to an articulated plow system wherein the moldboard is retained to the moldboard structure by a special retaining means that allows for easy replacement of the moldboard.
Finally, it is an object of the present invention to provide a U shaped articulated plow form so that a greater volume of snow can be collected between the wings or arms of the plow. This also makes it possible to contain and control the snow mass better and lends itself to ease of cleaning up the surface area from which the snow is being removed.
The inventors do not know of any prior art that either teaches or discloses the unique features of the present invention.
SUMMARY OF THE INVENTION
The present invention is an articulating snow plow system having several major features: a lighting system, a quick and easy connect/disconnect system, a reactive controlled pressure mechanism for applying a controlled pressure to the bottom edge of the moldboard of the plow, a simple electric control to activate or deactivate the reactive controlled pressure mechanism, a bell crank system for adjusting the attitude of the moldboard, a special retaining system for retaining the moldboard, a reactive pressure mechanism for articulating the wing segments of the snow plow in response to obstacles encountered by the plow, and a floating mechanism designed to provide the plow blades with a few degrees of float independent of the main support structure or frame.
Accordingly, the present invention may be summarized as an articulated snow plow system for use with a motorized vehicle. The articulated snow plow system comprising an articulated snow plow coupled to a reactive controlled pressure snow plow system for use with the articulated snow plow. The articulated snow plow having a moldboard and the reactive controlled pressure snow plow system including a reactive controlled pressure mechanism mechanically coupled to the vehicle and to the moldboard of the articulated snow plow. A reactive controlled pressure system for controlling the reactive controlled pressure mechanism by supplying and removing a non-compressible fluid from the reactive controlled control mechanism in response to changes exceeding a predetermined pressure range within the reactive controlled pressure mechanism. The reactive controlled pressure system being connected to the reactive controlled pressure mechanism.
The present invention may alternatively be described as an articulated snow plow system for use with a motorized vehicle comprising an articulated snow plow coupled to a quick mount system for mounting an articulated snow plow to a vehicle, the quick mounting system including a support mechanism coupled to the articulated snow plow and having at least three mounting points. A frame structure having at least three mounting points. A connecting mechanism connecting the mounting points of the frame structure to the mounting points of the support mechanism. The mounting points of the frame structure being connected to the mounting points of the support mechanism by the connecting mechanism. The support mechanism being connected to the vehicle and the frame structure being connected to the articulated snow plow.
The mounting system further including a lighting system comprising at least one light connected to a support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the subframe by the connecting means.
The reactive controlled pressure system further including a lighting system comprising at least one light connected to a support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the subframe by the connecting means.
The reactive controlled pressure system further including a quick mount system for mounting the articulated snow plow system to a vehicle, the quick mounting system comprising a support means for supporting the snow-plow, the support means having at least three mounting points. A frame having at least three mounting points. A connecting means for connecting the mounting points of the frame to the mounting points of the support means. The mounting points of the frame being connected to the mounting points of the support means by the connecting means. The support means being connected to the vehicle and the frame being connected to the snow-plow.
The reactive controlled pressure system further including a lighting system for connecting to the articulated snow plow system for use with a motorized vehicle, the lighting system comprising at least one light connected to a support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the sjibframe by the connecting means. The reactive controlled pressure snow-plow system can be activated or de-activated by an electric control switch.
Alternatively, the present invention may be described as a lighting system for use with an articulated snow plow system for use with a motorized vehicle, the lighting system comprising at least one light connected to a telescopically adjustable support frame. A subframe connected to the vehicle. A connecting means for rigidly connecting the support frame to the subframe. The support frame being connected to the subframe by the connecting means.
Also the present invention may be described as an articulated snowplow system for use with a vehicle comprising a mounting plow blade section having a moldboard section, at least two mounting sides, and at least one mounting structure located on each of the mounting sides. A plurality of extending plowblade sections each having a moldboard section and an engagement mechanism capable of engaging the mounting structure located on each of the mounting sides. An extending plowblade section being pivotally coupled to each mounting structure at the engagement mechanism.
The articulated snow plow system further including the combination of the engagement mechanism and the mounting structure, pivotally connected to each other, comprise: a hinge mechanism.
The articulated snow plow system further including the engagement mechanism and the mounting structure each comprise a series of sockets having openings. The sockets being aligned so that the spatial orientation of the openings of each socket is aligned along a substantially vertical axis; and a pin structure extending through each opening.
The articulated snow plow system further including an A-frame structure; (Any person reading or interpreting this patent should note that sometimes in this specification the plow support frame is referred to as the A-frame structure but it is not intended that-the scope of the invention disclosed and claimed herein be limited to that structure and that other frame structures could be substituted. Thus any frame structure which functions in a manner equivalent to the present structure should be considered to be literally within the definition of A-frame as used herein) at least one trip spring, and at least one pivot. The trip spring and the pivot being mounted to the mounting plowblade section independent of the A-frame.
The articulated snow plow system further including a support bracket . mechanism on the vehicle for receivably accepting a plow support frame. A plow support frame adapted for being coupled to the vehicle bracket mechanism and including an adjusting mechanism for adjusting the angular orientation of the mounting plowblade section and the extending plowblade sections. The mounting plowblade section coupled to the plow support frame and to the adjusting mechanism. A bell crank mechanism coupled between the front of the vehicle and a forward portion of the frame to permit vertical adjustment of the mounting plowblade section and the extending plowblade sections. A cylinder mechanism mounted to the frame and having a piston rod structure coupled to the bell crank mechanism for moving same to cause vertical adjustment, and fluid for extending and retracting the piston rod mechanism. A first bell crank coupling structure for coupling the bell crank mechanism to the vehicle bracket structure above the snow plow support frame structure (A-frame) and a second bell crank coupling structure on the frame generally adjacent the plow blade. The bell crank mechanism including a first link member which is coupled, at its first end, to the vehicle bracket structure by the first bell crank coupling structure and a second generally L-shaped link member having first and second ends. The second end of the first link member and the first end of the second link member being pivotally coupled to each other. The second end of the second link member being pivotally coupled to the piston rod of the first cylinder. The angular corner of the second link member being pivotally coupled to the second bell crank coupling bracket mechanism.
Alternatively, the above noted structure of the present invention could also be defined as a direct linkage system in which a short stroke actuator (e.g., a hydraulic cylinder) is used to provide a greater lift height to the snow plow as a result of the leverage of the linkage mechanism. For example, the actuator stroke could be limited four inches but the leverage could be adjusted so that the four inch stroke results in snow plow being lifted 20 inches. The amount of leverage affecting how much the snow plow may be raised could be varied depending upon the amount of additional linkage structure used or the length of the lever arm.
Consequently, an support frame structure used in the structure of the present invention which functions in a manner equivalent to the present structure should be considered to be literally with in the definition of support frame bracket mechanism of the present invention.
The articulated snow plow system having a substantially U shape when the extending plowblade sections are swept forward.
The articulated snow plow system further including a plurality of wearstrips. At least one wearstrip being mounted to the moldboard section of the mounting plowblade section and each extending plowblade section. The wearstrips being spatially orientated to overlap. The wearstrip of the mounting plowblade section has two ends and each end of the wearstrip overlaps a portion of the wearstrip of each extending plowblade section. The wearstrip of the mounting plowblade section having thickness of approximately of one (1) inch. Of course, this dimension is not critical. It is only important to note that the dimension should, preferably, be sufficient to prevent interference with the flow of snow across the moldboards of the plow when they are articulated to be angled either fully to the right or to the left.
The articulated snow plow system further including a plurality of hydraulic extension and retraction mechanisms each having a first end and a second end. The first end of each hydraulic extension and retraction mechanism being coupled to the mounting plowblade section. The second end of each hydraulic extension and retraction mechanism being coupled to a respective extending plow blade section. The hydraulic extension and retraction me cham sms being dual or double acting hydraulic cylinders.
The articulated snow plow system wherein the hydraulic extension and retraction mechanisms are coupled, via a plurality of hydraulic line structures, to a hydraulic control system. The hydraulic control system comprising a plurality of pressure switches, relief valves, and a reservoir. A hydraulic fluid being contained in both the hydraulic extension and retraction mechanisms, the hydraulic line structures, and the hydraulic control system. The hydraulic fluid capable of flowing into and out of the hydraulic extension and retraction mechanisms via the hydraulic line structures. At least one pressure switch mechanism being coupled to a valve mechanism. The valve mechanism being coupled to the hydraulic line structures and located between each the hydraulic extension and retraction mechanism and the reservoir. Each pressure switch mechanism capable of being actuated at predetermined pressure to actuate the valve mechanism coupled to a hydraulic line structure coupled to the reservoir. The hydraulic fluid capable of moving into the reservoir when the valve mechanism is open. The pressure switch mechanism (typically a pressure switch) is actuated by a predetermined increase in pressure greater than the forces encountered in normal plowing. In the specific structure disclosed herein this is a force exceeding approximately 1600 pounds per square inch of hydraulic fluid pressure.
The system of the present invention further includes pressure relief valves to permit hydraulic fluid to be directed to the reservoir in the unlikely event that a pressure switch fails and does not activate the valve mechanism to allow fluid to move into the reservoir. The pressure relief valve will activate if the system pressure reaches a level significantly higher than the pressure switch setting. For example, in the present system a 2000 psi pressure relief valve is used in conjunction with a 1600 psi pressure switch setting. When the hydraulic pressure exceeds the relief valve pressure limit the valve will open and dump the hydraulic fluid into the reservoir.
The articulated snow plow system further including a moldboard section of the mounting plowblade section having an upper edge and a lower edge. The moldboard sections of the plurality of extending plowblade sections having an upper edge and a lower edge. The moldboard sections having an upper portion and a lower portion and being fastened to the blade structure by a retaining mechanism, the retaining mechanism comprising a fastener and at least one lower retaining channel structure located on each the mounting plowblade section and on each the extending plowblade section, respectively. The fastener fastening the upper edge of the moldboard to the upper portion of the blade structure. The lower retaining channel structure comprises a channel presented between a wearstrip, coupled to the lower portion of the blade frame, and the blade frame. Additionally, a second or even a third moldboard could be placed between the moldboard and the blade frame. It should be noted that in the presently proposed commercial embodiment of the present invention the center section of the articulated plow is not designed to have a retained moldboard but that other embodiments could contain this feature without departing from the invention as disclosed and claimed herein.
The articulated snow plow system additionally including having a moldboard section of the mounting plowblade section having an upper edge and a lower edge. The moldboard sections of the plurality of extending plowblade sections have an upper edge and a lower edge. The moldboard sections being fastened to the blade structure by a retaining mechanism, the retaining mechanism comprising at least one upper retaining channel structure and at least one lower retaining channel structure located on each the mounting plowblade section and on each the extending plowblade section.
The mounting plowblade section and the extending plow blade sections each having an upper edge and a lower edge and a blade frame, respectively. The upper retaining channel comprising a channel presented between a retaining strip fastened to each respective upper edge and the blade frame.
Alternatively, the mounting plowblade section and the extending plow blade sections each having an upper edge and a lower edge and a blade frame, respectively. The lower retaining channel structure including a channel presented between a wearstrip mounted to the lower edge and the blade frame.
Alternatively, at least one of the moldboard section is comprised of a substantially clear material like LEXAN brand clear plastic material.
DESCRIPTION OF THE DRAWINGS
FIGS. 1-10 show various views of some of the features of the present invention in conjunction with a standard non-articulable plow blade system to provide background and to illustrate by comparison the advantages of the present invention.
FIG. 1 is a top plan view of a nonarticulable snow plow system.
FIG. 2 is a side plan view of the nonarticulable snow-plow system.
FIG. 3 is a schematic view showing the valve block and the main hydraulic or reactive constant pressure cylinder.
FIG. 4 is a rear plan view of the lighting system.
FIG. 5 is a schematic view of the electrical control circuit showing the circuit engaged in the blade down and float configuration.
FIG. 6 is a schematic view of the electrical control circuit showing the circuit engaged in the pressure down configuration.
FIG. 7 is a schematic view of the electrical control circuit showing the circuit engaged in the raise configuration.
FIG. 8 is a schematic view of the electrical control circuit showing the circuit engaged in the hold configuration.
FIG. 9 is a schematic view showing the hydraulic control system in the blade float configuration.
FIG. 10 is a schematic view showing the hydraulic control system in the pressure down configuration.
FIG. 11 is a schematic view showing the hydraulic control system in the raise and hold position.
FIG. 12 is side plan view of the vehicle bracket or subframe.
FIG. 13 is a schematic view of the hydraulic system of the articulated plow system.
FIG. 14 is a schematic view of the electrical system of the articulated plow system.
FIG. 15 is a side elevational view showing a retaining structure for retaining the moldboard on the articulated plow system.
FIG. 16 is a side elevational view showing the bottom portion of the retaining structure for retaining the moldboard on the articulated plow system.
FIG. 17 is a side elevational view showing an alternative retaining structure for retaining the moldboard on the articulated plow system.
FIG. 18 is a side elevational view of the bell crank lifting system used in combination with the articulated plow system in the lowered position.
FIG. 18A is a side elevational view of the bell crank lifting system used in combination with the articulated plow system in the raised position.
FIG. 19 is a schematic view showing the relationship of the hydraulic lines of the dual acting cylinders, which extend from the mounting plowblade section to the extending plowblade sections, and the valve block.
FIG. 20 is a side elevational view showing the blade center section (the mounting plowblade section), the pivot between the center blade section and the carrier, and the pivot and rubber torsion bushing carrier structure.
FIG. 20A is an exploded view showing the blade center section (the mounting plowblade section), the pivot between the center blade section and the carrier, and the pivot and rubber torsion bushing carrier structure.
FIG. 21 is a perspective view of the articulated plow system in the swept forward position.
FIG. 22 is a top plan view of the articulated plow system in straight plowing position.
FIG. 23 is a top plan view of the articulated plow system exaggerating the space between the wearstrip of the mounting plowblade section and the wear strips of the plurality of extending plowblade sections to illustrate that the wear strip of the mounting plowblade section overlaps the wearstrips of the extending plow blade sections.
FIG. 24 is a top plan view of the articulated snow plow system showing the extending plow blade sections in the swept forward position.
FIG. 25 is a top plan view of the articulated snow plow system showing the extending plow blade sections in the swept back position.
FIG. 26 is a top plan view of the articulated snow plow system showing one extending plow blade section in the swept back position and one extending plow blade section in the swept forward position for pushing snow off to one side of the plow vehicle.
DETAILED DESCRIPTION
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
Referring to FIGS. 1-12, some of the features of the present invention may be seen in combination with a nonarticulated plow system as previously disclosed in U.S. patent application Ser. No. 08/225,215, filed on Apr. 8, 1994 now abandoned.
The main features of the nonarticulated snow plow system 10 are a lighting system 20, a mounting system 40, a reactive controlled pressure system 60, and an electronic control for engaging and disengaging the controlled pressure system 70. The. nonarticulated snow plow system 10 further includes a moldboard 100 and an A-frame 14 for supporting and connecting the components of the nonarticulated snow plow system 10.
The nonarticulated snow plow system 10 is connected to the frame of the vehicle 11 with mounting system 40. Referring to FIGS. 2 and 12 the nonarticulated snow plow system 10 may be seen to be connected to the vehicle 11 by a mounting subframe 12 that is fixedly connected to the frame of the vehicle 11. The mounting system 40 is integral to the A-frame 14 as shown in FIG. 1. The subframe 12 has mounting points 16-18 having openings 50-52 as shown in FIG. 12. The mounting system 40 has three mounting points 41-43, having openings 44-46, and three mounting pins 47-49. Mounting points 16-18 of the subframe 12 correspond to mounting points 41-43 of the mounting system 40 so that openings 50-52 align respectively with openings 44-46. Pins 47-49 pass through the aligned openings 50-52 and 44-46. Locking pins 53-55 are respectively used to hold the pins 41-43 in place in the openings 50-52 and 44-46 during operation of the vehicle 11. In this manner the nonarticulated snow plow system 10 of the present invention is quickly and easily mounted to the vehicle 11 so that there is a rigid and fixed connection between the vehicle 11 and the nonarticulated snow plow system 10 through the mounting subframe 12 which is attached to the frame of the vehicle 11.
Referring now to FIGS. 1, 2, and 4 the lighting system 20 may be seen to comprise a set of high intensity light road lights 22 mounted to a support frame 24. Any type of lights 22 providing sufficient illumination could be used. The lights 22 are powered from the vehicle 11 in a known manner. The support frame 24 has two mounting points 25-26 having openings 28-29. As specifically shown in FIGS. 1 and 2 the mounting points 25-26 line up with the mounting points 41 and 42 of the mounting system 40. Accordingly, the support frame 24 is fixedly and rigidly mounted to the subframe 12 by the same mounting system 40 as is the rest of the nonarticulated snow plow system 10 by the pins 47 and 48 of the mounting system 40. In this manner the lighting system 20 is rigidly and fixedly mounted to the vehicle 11 with the lights 22 positioned to shine over the top edge 102 of the moldboard 100 and at the same time being set off from the body of the vehicle 11 to minimize any obstructions to the vehicle operator's field of vision.
Further, referring specifically to FIG. 2, the support frame 24 may be seen to include two posts 36 that are telescopically adjustable to move the lights 22 vertically up or down with respect to the plow system 10. A plurality of openings 37 extend up and down the sides of the posts 36. Once the proper height for the lights 22 has been determined the openings 37 in the telescoping posts 36 are aligned with openings 39 in support frame 24 and bolts 38 are passed through the openings 37 and 39. Each bolt 38 is secured by using a nut. This holds the lights 22 in the vertical position desired. Accordingly, the lighting system 20 of the present invention may be easily adjusted to the needs of the individual vehicle operator and in order to obtain maximum illumination of the area in front of the vehicle regardless of the snow plow's position.
Referring to FIGS. 1-3 and 5-12 the reactive controlled pressure system 60 may be seen to comprise an electrical control unit 70, a hydraulic control/power unit 80, and a hydraulic cylinder linkage 90. As can be seen in FIG. 2, hydraulic cylinder linkage 90 includes a bell crank 95 to aid in the effective transference of weight or force from the mass of the vehicle 11 to the bottom edge 101 of the moldboard 100. While a bell crank 95 is the means of mechanical linkage disclosed, it is not the only possible means for accomplishing the same function.
The electrical control unit 70 is shown schematically in FIGS. 5-8. The electrical control unit 70 operates off the battery power of the vehicle 11 and is energized when the vehicle ignition key is turned to the accessory setting or when the engine of the vehicle 11 is running. The electrical control wiring harness 65 includes a plug 66 and a receptacle 67 that can be separated when the snowplow system 10 is removed from vehicle 11. As shown in FIGS. 5-7B, the electrical control unit 70 has two switches 61 and 62 that control the hydraulic lift and reactive pressure control unit 80.
The hydraulic control/power unit 80 is connected to the reactive controlled pressure mechanism or hydraulic cylinder 91 by hoses 81 and 82. The hydraulic control unit 80 supplies non-compressible fluid, hydraulic oil, to the cylinder 91. Hydraulic cylinder linkage 90, a bell crank, is connected to hydraulic cylinder 91. The hydraulic control/power unit 80 is located in cradle 80a, best seen in FIGS. 18 and 18a, and is positioned to be forward and of the vehicle to which the present invention is mounted. This removes effective weight from the vehicle and to the wearstrip of the plow as well as aiding in maintaining the vehicle's center of gravity, as designed in the vehicle by the vehicle manufacturer.
The reactive constant pressure system works as follows:
To raise the plow moldboard 100 the operator actuates switch 61 as shown in FIG. 2 to the up position. Now referring to FIG. 11, the four way valve 110 and the two way valve 111 are de-energized. The switch 62 can be in either position when the switch 61 energizes the pump 112, valve 111 blocks the flow to the reservoir 120. This causes the oil to flow into valve 110 from port 3 and out of valve 110 through port 2 into the rod end 92 of the cylinder 91. This lifts the plow moldboard 100. The opposite end of the cylinder 91 is open to the reservoir 120 through ports 4 to 1. When the cylinder 91 is completely extended the pump 112 is turned off by releasing the control switch 61.
To hold the plow moldboard 100 in a raised position for transport, the switch 61 is held in a neutral position and the switch 62 can be in either position as shown in FIG. 8. This position de-energizes the pump 112 and the valves 110 and 111. Valve 111 blocks oil flow to the reservoir so that the raised position of the plow is maintained. See FIG. 11.
To float the plow moldboard 100 so that it is in the down position but has no down pressure on it, the control switch 61 is depressed to the down position and control switch 62 is depressed to the float position. See FIG. 5. Referring to FIG. 9, this energizes valve 111 and de-energizes valve 110. Energizing valve 111 opens the rod end 92 of the cylinder 91 to the reservoir 120. Thus both ends of the cylinder 91 are connected to the reservoir 120 and the moldboard 100 will float.
To apply a predetermined down pressure to the plow moldboard 100, the control switch 61 is depressed to the down position and control switch 62 is depressed to the pressure position as shown in FIG. 6. This energizes the four way valve 110 and connects a pressure switch 121 to the pump activating circuit as shown in FIG. 10. Energizing valve 110 reverses the flow of oil from the pump 112 to the opposite end 93 of the cylinder 91 putting a predetermined amount of pressure upon the bottom edge 101 of the plow moldboard 100.
When the pressure on the piston 94 of the hydraulic cylinder 91 reaches the predetermined pressure that has been set, the pressure switch 121 activates and opens the circuit stopping the pump 112. The check valve 130 in the line prior to valve 110 retains the oil in the piston 94 so that the there is a controlled predetermined pressure maintained on the bottom edge 101 of the moldboard 100.
If the bottom edge 101 of the moldboard 100 rises, e.g. due to a change in road surface, sufficient to increase the pressure within the cylinder 91 beyond a predetermined high pressure setting, then the relief valve 122 opens and oil is allowed to flow back into the reservoir 120 until the pressure in the cylinder 91 drops down to below the predetermined high pressure setting.
Once the situation causing the high pressure abates, the pressure can drop down to a predetermined low pressure setting when the bottom edge 101 of the moldboard returns to a normal plowing position. At this predetermined low pressure the pressure switch 121 again activates the pump 112 and oil is pumped from the reservoir 120 into the cylinder 91 until the predetermined nominal pressure is again reached.
It should be noted that it is not necessary for there to be a pressure increase before there is a pressure drop. If the plow moldboard 100 drops into a depression on the surface being plowed, the oil pressure in the cylinder 91 could drop below the predetermined minimum setting. This drop would also be sensed by the pressure switch 121 and cause activation of the pump 112 to increase the pressure in the cylinder 91 back up the predetermined nominal pressure setting.
Furthermore, it should be noted that the plow moldboard 100 can be raised without releasing control switch 62 from the pressure position. By merely depressing control switch 61 to the up position, the plow moldboard 100 is lifted without disengaging the down pressure system. When the moldboard 100 is subsequently lowered, the predetermined downward pressure is again applied to the bottom edge 101 of the plow moldboard 100.
In its specific embodiment the pressure differential is set so that the difference between the highest internal pressure in the cylinder 91 and the lowest internal pressure will allow the plow moldboard 100 to follow the surface contour of the road over small variations without activating the pump 112 or relief valve 122 and yet react to maintain a nearly constantly controlled pressure upon the bottom edge 101 of the plow moldboard 100.
In the preferred embodiment, the nominal pressure setting is 500 psi, the low pressure setting is 450 psi, and the high pressure setting is 600 psi. It is to be understood, however, that different pressure settings can be used to obtain the optimum weight transfer if this system is used with heavier or lighter weight snow plows or if the geometry of the lift mechanism is changed.
Referring now to FIGS. 13-26, it may be seen how the above noted innovations, as well as other novel concepts, may be combined with an articulated plow system 500.
Referring to FIG. 13, the hydraulic control unit or system 80 may be seen to be modified from the hydraulic control system 80 previously discussed in FIGS. 9-11. As may be seen FIG. 13, the hydraulic control unit 80 for the articulated plow system 500 now further includes, in addition to the structures disclosed in FIGS. 9-11, a left angle cylinder 220, a right angle cylinder 221, 1600 psi pressure switches 222 and 223, four 1500 pound per square inch (psi) crossover relief solenoid valves 224-227, two 2000 psi reservoir dump valves 222a and 223a, a left angle cylinder extension solenoid 228, a left angle cylinder retract solenoid 230, a right angle cylinder extension solenoid 229, a right angle cylinder retract solenoid 231, a 1750 psi system relief solenoid valve 232 (previously disclosed in FIGS. 9-11), and an intake filter 240 (previously disclosed in FIGS. 8-10).
Referring now to FIG. 14, a wiring schematic for the articulated plow system 500 may be seen. As may be understood by reference to FIGS. 5-8 the wiring schematic for the electrical control unit 70 has been modified to provide for the desired unique functions of the articulated plow system 500.
The electrical control unit 70 for the articulated plow system 500 includes an ignition 250, a control box 260, a right cylinder extend and retract switch 261 having. a toggle 261a and a retract contact 263 and an extend contact 265, a left cylinder extend and retract switch 262 having a toggle 262a and a retract contact 264 and an extend contact 266, a left cylinder pressure switch 222, a right cylinder pressure switch 223, a system indicator light 251, the vehicle battery 252, the vehicle ground 253, a hydraulic power unit ground 254, and a hydraulic power unit 255. Further, it should be noted that switch 61 has a plow down position contact 61a, a toggle 61b, and a plow up contact 61c. Switch 62 has a down pressure engagement contact 62a, a toggle 62b, and plow down and float contact 62c.
Referring now to FIGS. 15-17, a unique combination of the articulated plow system 500 with a mounting system for mounting the moldboard 100 may be seen. The combination may be seen to be comprised of the moldboard 100 having a top a edge 102 and a bottom edge 101, a retainer strip 180, a wearstrip 182 having a bottom edge 181, a channel 190, a blade frame 184 having an upper edge 195 and a lower edge 194, bolts 186 and 188, nut 187, slot 189, and ribs 183. Each section 300, 350, and 400 of the articulated plow system 500 is collectively identified in FIGS. 15-17 by blade section 185 since this mounting system may be used individually on each respective section 300,350, or 400 of the articulated plow system 500. Reference number 185a indicates the lower edge of each plow blade section 185. However, it should be noted that in the presently proposed commercial embodiment of the present invention 10 only sections 300 and 400 are envisioned to use the above noted mounting system.
Referring specifically to FIG. 15, the retaining system works by sliding the moldboard 100 into the channel 190 and then placing retainer strip 180 over the top edge 102 of the moldboard 100 by mounting it to the upper edge 195 of the blade frame 184 with the bolt 188. Alternatively, the moldboard 100 may be retained by sliding the moldboard 100 into the channel 190, as noted above, but providing slots or openings 189 along the top edge 102 of the moldboard 100 through which the retaining bolt 188 may pass directly into the upper edge 195 of the blade frame 184.
Referring to FIG. 16, the channel or gap 190 presented between the lower edge 194 of the blade frame 184 and the wearstrip 182 may be seen. This mounting system presents a unique mounting structure for mounting a moldboard 100 to an articulated plow system 500. It allows a person using the plow system 500 to easily replace a moldboard 100 on any section 185 of the plow system 500 or to even stack moldboards 100, if desired, on the plow system 500.
Referring now FIGS. 1,2, 18, 18A, and 21 the bell crank lift system used in combination with the present invention may be seen. The bell crank lift system is specifically disclosed in FIGS. 18 and 18A but reference should also be made to FIGS. 1,2, and 21 to understand the relationship of the various parts of the bell crank lift system as disclosed herein.
The bell crank lift system of the articulated snow plow system 500 is coupled between the front of the vehicle (not shown), at the subframe 12, and a forward portion of the A- frame 14 to permit vertical adjustment of the mounting plowblade section 400 and the extending plowblade sections 300 and 350. A cylinder 91 has a piston rod 774 The cylinder 91 is coupled at an end 773 to end 773c of bell crank 95 and at end 775 to the A-frame 14 for moving the bell crank 95 to cause vertical adjustment of the articulated plow system 500 of the present invention. Hydraulic fluid for extending and retracting the piston rod 774 is supplied to the cylinder 91 through hoses 81 and 82, shown best in FIG. 2. The bell crank lift system of the present invention further includes a first link 787 which is coupled, at point 43, to the vehicle subframe 12. First link 787 is also coupled to a second generally L-shaped link member 95, having end 773b, end 773c, and corner structure 773a, at end 773b. First link 787 being pivotally coupled to L-shaped link member 95 at end 773b. End 773c, as noted above, is pivotally coupled to the cylinder 91 at end 773. The angular corner 773a of the L-shaped linkage 95 is pivotally coupled to a bell crank coupling bracket structure 775 at corner 773a. Accordingly, hydraulic fluid may be added to or removed from the cylinder 91 through hoses .81 and 82 in order to raise or lower the A-frame 14 and the plow system 500 is response to the conditions presented.
Referring now to FIG. 19 an exploded schematic view of the hydraulic system of the articulated snow plow system 500 may be seen. FIG. 19 shows that the hydraulic system includes right cylinder retraction line 304, left cylinder retraction line 354, right cylinder extension line 306A and 306, left cylinder extension line 356A and 356, pump line 308 to pressure switch 223, pump line 358 to pressure switch 222, right wing cylinder 302, left wing cylinder 352, pump line 360 to the down pressure valve block 362, drain line 364 to reservoir 120, hydraulic line 81 to cylinder 91 for providing hydraulic fluid to extend cylinder 91, and hydraulic line 82 to cylinder 91 for providing hydraulic fluid to retract cylinder 91. Further, 2000 psi relief valves 222A and 223A are provided between lines 356A, 356 and 306A, 306, respectively. Lines 356A,356 and 306A,306 each respectively and effectively operate as one contiguous hydraulic line, however, when there is a substantial pressure within the hydraulic system (in the specific embodiment disclosed herein the specific pressure is in excess of 2000 psi) either or both relief valves 222A and 223A will open to line 357A which is connected to hydraulic line 357. This will dump excess hydraulic fluid into the system reservoir 120 and relieve the excess pressure within the system.
Referring now to FIGS. 20, 20A, and 21, blade center section 400 may be seen to include pivot 402, spring mounting plate 424 having opening 424a, left hinge set 430, right hinge set 432, right cylinder coupling 436, and left cylinder coupling 435. Intermediate pivot assembly 450 may be seen to comprise pivot 402a, pivot 404, rubber torsion bushing 406, mounting plate 415 having openings 415a. Also springs 410 with hooks 420 and 422, adjustment bolts 412, adjusting nuts 414 and 416, mounting plate 418 (integral to bolt 412) having opening 418a may also be seen as well as the front portion of A-frame 14 with pivots 404a and the noted gaps 408 between A-frame 14 and intermediate pivot assembly 450.
Springs 410 are mounted on hooks 420 and 422 and extend from mounting plate 424 to mounting plate 418. Mount plate 418 is integral to bolt 412. Tension on springs 410 can be adjusted by use of adjusting nuts 414 and 416 which secure bolt 412 in opening 415a of mounting plate 415. Accordingly, pivot 402 allows the center section 400 to pivot when the articulated plow 500 trips and spring 410 and its mounts will bias the center section 400 back to operating position.
Additionally, pivot 404 of intermediate pivot assembly 450 acts as an intermediate pivot between the center section 400 and the A-frame 14 which allows a few degrees of motion about a horizontal axis defined by the pivot 404 and 404a to permit, in combination with gap 408, a limited amount of float, roughly 5-6 degrees, which allows the articulated plowblade sections 300 and 350 and the blade center section 400 to follow the contour of the ground and also allows for some variation in the mounting height of the vehicle mounting points, rubber torsion bushings 406 provide some resistance to float and reduce the probability of unnecessary motion of the plowblade sections 300, 350, and 400.
Referring now to FIGS. 21-26, the articulated snow plow system 500 may be seen to generally comprise a center section 400 hingedly mounted to a right wing plowblade section 300 and a left wing plow blade 350 by hinges 432 and 430, respectively. As these drawings clearly show the center section of the system 500 has two pivots at hinges 432 and 430 instead of one pivot as shown in the prior art.
The center section 400, right wing section 300, and left wing section 350 each include a wearstrip 182. Referring to FIG. 23, it may be seen that the wear strip 182 of the center section 400 has side portions 182a and 182c which respectively overlap end portions 182b and 182d of the wearstrip 182 of the right wing 300 and the left wing 350. Accordingly, the overlapping wearstrips 182 give complete coverage of the ground surface in front of the plow system 500. No gaps are presented so there is no missed coverage and/or strips of snow remaining on the ground surface.
As illustrated in FIGS. 21-26, the wearstrip 182 of the center section 400 is positioned forward of the wearstrips 182 of the left and right plowblade sections 300 and 350. This allows the wearstrips 182 of the plowblade sections 300 and 350 to move without presenting gaps. Also, it is preferred, but not necessary, that the wearstrip 182 of the center section 400 be positioned at a shallower angle, roughly 45 degrees from vertical, than the wearstrips 182 of plowblade sections 300 and 350, which are positioned approximately 25 degrees from vertical, to permit better lifting of hard packed snow at the center section 400. Consequently, in a swept back position, as illustrated in FIG. 25, there would be greater mechanical advantage given to the center section in making the initial contact with the snow or other material to be plowed.
With respect to the actuation of the down pressure system with respect to the articulated plow system 500, the down pressure system is actuated in the same manner as described with respect to FIGS. 1-11 supra. Further, the lifting of the plow system 500 is the same as described with respect to the plow system disclosed in FIGS. 1-11. However, the present plow system 500 also has a pressure sensing ability to permit blade tripping when in the scoop position, as shown in FIG. 24, or when in the system 500 is fully angled in a particular direction as illustrated in FIG. 26.
When one or both wings 300 or 350 are swept forward and in that position strike an object the force from striking the object increases the pressure on the cylinder of the respective wing struck. This results in increased hydraulic pressure in the particular cylinder and hydraulic line on the extend side 228 or 229 (see FIG. 13). When this pressure exceeds 1600 psi (this value may vary depending upon the size and type of system that is used to achieve the desired function) in pressure the contacts of the respective pressure switch, 222 and/or 223 close. This completes the circuit illustrated in FIG. 14 to the two solenoid valves 228 and 229 which allows the hydraulic fluid to be dumped into the reservoir 120. This causes the wings 300 and 350 to be retracted to more straight position like those shown in FIGS. 22 and 23. In this position the normal mechanical tripping action can occur.
Additionally, this allows a wing 300 or 350 to react to the striking of an object by pulling away from that object with a movement that is opposite to the forward motion of the vehicle. This allows some relief from the force of the object struck by the wing. This feature can be used on a plow having a single pivot point as well as the plow system 500 disclosed herein.
The above described embodiments of this invention are merely descriptive of its principles and are not to be limited. The scope of this invention instead shall be determined from the scope of the following claims, including their equivalents. | An articulated snow plow system for use with a vehicle includes a blade center section having a moldboard section and left and right plowblade sections which are wider than the blade center section. The plowblade sections each include a moldboard section and are mounted to the blade center section at opposite sides thereof and pivotable relative to the center blade section about a substantially vertical pivot axis, to swept forward and swept backward positions. The snowplow assembly includes a support frame, the blade center section being coupled to the support frame through an intermediate pivot assembly which permits a limited amount of float to allow the blade center section, and the plowblade sections pivoted thereto, to follow the contour of the ground. Pressure sensors associated with hydraulic cylinders which move the plowblade sections between extended and retracted position, respond to pressure within the hydraulic cylinder for the associated plowblade section exceeding a trip point to cause both of the plowblade sections to be retracted to a more straight position. | 4 |
This invention relates to an exhaust nozzle for a gas turbine engine and is particularly, although not exclusively, concerned with such an exhaust duct for use in circumstances in which a reduced IR (infra-red) and RCS (Radar Cross Section) signature is desirable.
BACKGROUND
It is known to take various measures to reduce the IR and RCS signatures of ‘stealth’ aircraft such as UCAVs (Unmanned Combat Air Vehicles). The engine exhaust of such aircraft is a significant contributor to the IR signature, and it is known to take measures to reduce the temperatures of both the exhaust gases issuing from the exhaust nozzle and of the aircraft components surrounding the exhaust nozzle. This has been achieved in the past by constructing the exhaust nozzle as a twin-walled structure, so that cooling air can flow between the walls, to emerge into the exhaust gas flow through effusion cooling holes in the inner wall. The inner wall has been constructed as a liner made up of a plurality of tiles supported from the outer wall or nozzle casing of the engine.
In a previous proposal, the nozzle casing of an exhaust nozzle for a UCAV has a generally trapezoidal flow cross-section defined by top and bottom walls and a pair of side walls which interconnect the top and bottom walls. The side walls are relatively short in the flow direction, and the top and bottom walls have V-shaped profiles projecting beyond the side walls in the downstream direction (with respect to gas the direction of flow through the nozzle).
The liner in the previous proposal is at generally the same distance from the nozzle casing around the circumference of the nozzle. Consequently, as seen in cross-section, the flow passage for the cooling air has a constant width around the exhaust nozzle.
The nozzle casing needs to be very stiff, particularly at the nozzle exit, in order to maintain its alignment with the airframe in which it is installed, and to avoid excessive loads on the liner. The nozzle casing needs to be sufficiently stiff to resist pressure loads which tend to deform it outwardly, to assume an oval cross-section. Furthermore, the cooling air pressure tends to deflect the overhanging downstream end portions of the top and bottom wall portions in the direction away from the exhaust centreline, while the same cooling air pressure tends to deform the liner in the direction towards the exhaust centreline. The result of these effects is to widen the gap between the nozzle body and the liner, particularly in the downstream end regions, and this can increase the RCS signature and can also allow the uncontrolled escape of cooling air from the cooling passage. Distortion of the nozzle casing upsets the aerodynamics of the exhaust nozzle, affecting the distribution of cooling air over the liner and into the exhaust gas flow.
In order to achieve adequate stiffness in the nozzle casing of the previous proposal, the nozzle casing has a substantial thickness, and is consequently heavy.
SUMMARY
If the width of the cooling passage is determined so as to provide an adequate flow rate of air in the region of greatest requirement, i.e. at the central regions of the top and bottom wall portions, where the length in the exhaust gas flow direction is greatest, then this width will be larger than necessary in the regions where there is a lower flow requirement, for example at the side walls.
According to the present invention there is provided an exhaust nozzle for a gas turbine engine, the exhaust nozzle comprising a nozzle casing having top and bottom walls and side walls which interconnect the top and bottom walls, characterised in that at least one of the top and bottom walls comprises at least two mutually inclined planar wall portions which meet each other at a crease extending parallel to the flow direction through the exhaust nozzle, and a liner ( 4 ) disposed within the nozzle casing ( 2 ) to provide a cooling passage ( 18 ) between the nozzle casing ( 2 ) and the liner ( 4 ), the liner ( 4 ) being planar over the extent of the respective top or bottom wall ( 6 , 8 ).
The exhaust nozzle includes a liner spaced from the nozzle casing to define a cooling passage, the liner preferably being provided with effusion holes to enable air flowing in the cooling passage to pass into exhaust gas flowing through the exhaust nozzle. Preferably, the width of the cooling passage is smaller at the side walls than adjacent the crease in the top and/or bottom wall. The liner is generally planar across the extent of the respective top or bottom wall.
The planar wall portions are preferably inclined at an angle close to, but less than, 180°. In a preferred embodiment, wall portions are inclined at an angle of not less than 160°, and more preferably at an angle of not less than 172°. The angle between the planar wall portions preferably opens inwardly of the exhaust nozzle.
The planar wall portions preferably extend from the crease to the respective side walls, and consequently together constitute the entire top or bottom wall. Preferably, both the top and bottom walls comprise two mutually inclined planar wall portions meeting at a crease.
The trailing edge of each of the top and bottom walls preferably comprises two edge portions disposed in the form of a V, each edge portion extending obliquely inwardly with respect to the exhaust nozzle centreline, and downstream with respect to the exhaust gas flow direction, from the respective side wall to an apex lying on the crease.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 is a perspective view of an exhaust nozzle in accordance with the present invention;
FIG. 2 is a cross-section taken on the line II-II in FIG. 1 ;
FIG. 3 (PRIOR ART) is a cross-section corresponding to the line IV-IV in FIG. 1 but showing an exhaust nozzle in accordance with a previous proposal; and
FIG. 4 is a cross-section taken on the line IV-IV, showing the exhaust nozzle in accordance with the present invention.
DETAILED DESCRIPTION
The exhaust nozzle shown in FIGS. 1 , 2 and 4 comprises a nozzle casing 2 to which is secured a liner 4 . The liner 4 may, for example, be made up of a plurality of individual tiles supported independently by the nozzle casing 2 .
The nozzle casing 2 comprises a top wall 6 , a bottom wall 8 and a pair of side walls 10 which interconnect the top and bottom walls 6 , 8 and which slope inwardly from top to bottom so that the exhaust nozzle overall has a generally trapezoidal cross-section. References in this specification implying upwards and downwards directions relate to the orientation of the exhaust nozzle when installed in an aircraft in level flight.
The top and bottom walls 6 , 8 extend beyond the side walls 10 in the downstream direction, with respect to the direction of gas flow through the exhaust nozzle. Thus, the top wall 6 has a projecting or overhanging region 12 constituted by two oblique edges 14 which meet at an apex 16 so that the trailing edge of the top wall 6 has a shallow V-shaped configuration. The trailing edge adjacent the edges 14 is scarfed so that the exhaust nozzle can be integrated with the airframe in which it is installed. The bottom wall 8 has a similar shallow V-shaped configuration at its trailing edge terminate at an apex 17 , although, as is clear from FIG. 2 , the top wall 6 projects further in the downstream direction than the bottom wall 8 .
The nozzle casing 2 and the liner 4 define between them a cooling passage 18 . The cooling passage 18 receives cooling air, for example from the engine bypass, at its upstream end, and this cooling air flows through the cooling passage 18 to emerge from effusion holes (not shown) which allow the air to pass through the liner 4 into the stream of exhaust gas passing through the exhaust nozzle. The loss of air from the cooling passage 18 to the exhaust gas flow reduces the volume flow rate in the downstream direction, and consequently the cooling passage 18 is tapered as shown in FIG. 2 .
In accordance with a previous proposal, shown in FIG. 3 , the top and bottom walls 6 , 8 of the nozzle casing 2 are substantially planar, or flat, over their full extent, and the liner 4 is positioned within the nozzle casing 2 so that, as seen in transverse cross-section, the cooling passage 18 has a generally constant width around the nozzle. However, in accordance with the present invention, as shown in FIGS. 1 and 4 , the top and bottom walls 6 , 8 are non-planar. Thus, the top wall 6 comprises two planar wall portions 20 , 22 which are inclined to one another at an angle α which is close to, but less than 180°. In the illustrated embodiment, the angle α is 176°, but other angles of inclination are possible. Similarly, the bottom wall 8 comprises two planar wall portions 24 , 26 which are inclined to each other at an angle β which, in the embodiment shown, is 177° although, again, different angles of inclination are possible.
The wall portions 20 , 22 and 24 , 26 meet one another at respective creases 28 , 30 which, as can be appreciated from FIG. 1 , extend over the full length of the respective top and bottom walls 6 , 8 . The apices 16 , 17 of the downstream edges of the top and bottom walls 6 , 8 lie on the creases 28 , 30 respectively.
The creases 28 , 30 significantly increase the rigidity of the top and bottom walls 6 , 8 , and so enhance the ability of the top and bottom walls 6 , 8 to resist deflection away from the centre line of the exhaust nozzle under the pressure loading applied by the cooling air in the cooling passage 18 .
Furthermore, as is apparent from FIG. 4 , the inclination of the wall portions 20 , 22 and 24 , 26 means that, for the same profile of the liner 4 , the cooling passage 18 tapers, as seen in transverse cross-section, from the crease 28 , 30 towards the side walls 10 . Furthermore, the side walls 10 can be displaced inwardly (by comparison with the prior proposal of FIG. 3 ) to reduce the width of the cooling passage 18 even further). The result of the varying width of the cooling passage 18 is that regions of the cooling passage 18 which supply a relatively large area of the liner 4 , and consequently a relatively large number of effusion holes, can be provided with a relatively large cooling air flow cross-section. Such areas are those adjacent to the creases 28 , 30 , where the length of the liner 4 in the gas flow direction is greatest.
By contrast, regions of the cooling passage 18 which supply air to smaller areas of the liner 4 , such as the region adjacent side walls 10 and the outer regions of the top and bottom walls 6 , 8 , have smaller flow cross-sections.
Consequently, by appropriately inclining the top and bottom wall portions 20 , 22 and 24 , 26 , the distribution of cooling air around the liner 4 can be made more consistent, while at the same time increasing the stiffness of the nozzle casing 2 . Although FIG. 4 shows angles α and β in excess of 175°, smaller angles may be appropriate in some circumstances, depending on the degree of stiffness required and on the desired distribution of cooling air.
The increased stiffness of the top and bottom walls 6 , 8 afforded by the creases 28 ; 30 provides better control of the movements of the nozzle casing 2 and of the liner 4 under both pressure and thermal loading, particularly at the nozzle exit apices 16 and 17 .
Because the cooling passage 18 can be reduced in width in the region of the side walls 10 , the overall size of the nozzle may be reduced by comparison with the embodiments shown in FIG. 3 , so making it easier to integrate the exhaust nozzle into the airframe. Also, the stiffness achieved by the creases 28 , 30 allows the thickness, and therefore weight and cost, of the nozzle casing, to be reduced.
Although the invention has been described in the context of an exhaust nozzle including the liner 4 , it may also be applied to nozzles without liners. Also, although only a single central crease 28 , 30 has been shown in each top and bottom wall 6 , 8 , more than one crease, consequently more than one planar wall panel, may be provided. | An exhaust nozzle for a gas turbine engine includes a nozzle casing having top and bottom walls and side walls. A liner is provided within the nozzle casing to define a cooling passage. The top and bottom walls each include mutually inclined planar wall portions which meet at respective creases. The creases increase the rigidity of the top and bottom walls. In addition, the inclined wall portions cause the cooling passage to taper in the direction outwardly from the creases, so assisting in the cooling air distribution over the liner. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to holders, and more specifically to holders for holding plastic shopping bags easily and conveniently.
2. Background Art
Plastic shopping bags have become ubiquitous to the shopping experience. Often, and especially when a shopper is leaving a grocery or department store, the shopper is required to hold a great number of bags, the number being in excess of the number of fingers for holding each bag. Moreover, as the thickness of the plastic shopping bags decreases to effect cost savings to the store, the shopper may experience an unpleasant sensation of the plastic cutting into the fingers as the plastic bag “handle,” usually just a hole in the plastic material forming the bag, bunches up and creates a sharp “edge”. When holding a number of such bags, the intense pressure on the shopper's fingers may be sharp enough to cut off the circulation of blood therein.
Another difficulty is experienced after the shopper has reached his or her vehicle in the parking lot, and has deposited the shopping bags into the trunk or baggage compartment. Upon arrival at the destination, the shopper must once again gather up the shopping bags by inserting the fingers through each of the bag handle holes, two for each bag, before carrying the bags to the final destination, e.g., the shopper's home. Care must be taken to ensure that each of the two handles, for each bag being transported, is engaged because lifting a bunch of bags when one is not being held, or is being held by one handle hole only, may lead to a bag falling to the ground or being emptied of its contents, and possibly the breaking of containers made of glass or plastic, and thereby requiring cleanup of the contents and broken glass. Thus, a method is needed to retain the bags in a position that would make it easy and convenient to pick them up, while ensuring that all of the bag handles are engaged so as to avoid having a bag slip from the shopper's hold or opening to disgorge its contents.
The prior efforts to address these problems have been by and large unsuccessful in solving these problems in an efficient and effective way. For example, some of these bag holders are open ended holder that provides for carrying bags having handles or other items. However, because the bag holder does not provide a complete enclosure, leaving a gap out of which the bag handles may escape, placing the bags when in the holder on a surface, for example the floor of a vehicle, cannot ensure that all of the bags will remain in engagement when the shopper picks up the bags to transport them from the vehicle.
Other attempts to solve these problems utilize a handle central portion with two hooks on the ends for engaging the bag handles. However, these bag holders have a hook end that returns to the handle, where it is held in place by the shape of the hook. The only impediment to the bag handle becoming loose and slipping out of the hook enclosure is the integrity of the plastic material comprising the holder. Because the clip portion of the plastic holder is thinner at the end which engages the handle portion, it is liable to bend when a force, such as the weight of a bag containing heavy purchases, acts against the closing force of the handle hook. Thus, a shopper would be required to confirm that all bags are engaged by the hook before picking up the handle. Moreover, the shape of this type of handle requires a balanced load on each hook on either side of the handle, otherwise the shopper will be forced to support the handle in an uneven manner.
What has been found lacking and what is disclosed and claimed herein is a bag holder that can provide the benefits of an easy to hold and carry bag holder which has a positive locking mechanism to hold the bags in place at all times, that moreover is easily loaded and unloaded by the shopper; and which retains the bags with the assurance that none of the handles have gone astray.
SUMMARY OF THE INVENTION
Accordingly, what is disclosed and claimed herein is a bag holder comprising a main enclosure body for practically enclosing a space shaped and configured to hold bags by their handles, the space being essentially surrounded by said main enclosure body, said main enclosure body having two ends proximate to each other, said two ends being separated by a gap, a retractable clip member connected to a first one of said main enclosure body ends and being capable to extend to and engage the second end such that engagement of the clip with the second end completes the enclosure formed by the main enclosure body, wherein the clip member is selectively positioned by the user as to open or close the gap. In a method of use, the method of holding bags by their handles comprises the steps of providing an enclosure in a main enclosure body essentially enclosing a central space, and having a gap between two ends thereof, providing a retractable clip that can selectively open and close the gap between the main enclosure body ends, opening the gap by retracting the clip, placing the bag handle into the central space, returning the clip from the retracted position to a closed position in which the enclosure around the central space is secured and lifting the bags by grasping the main enclosure body and lifting.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Accordingly, the following disclosure is to be considered with reference to the drawing figures in which:
FIG. 1 is an elevational plan view of a bag holder according to the present invention;
FIG. 2 is a cross-sectional view of a portion of the bag holder body according to the present invention;
FIG. 3 is a detailed perspective view of the clip portion of the bag holder, shown in the open position ready to receive bags into the central space.
FIG. 4 is a cutaway view of an alternate embodiment of the clip portion of the bag holder, shown in the open position ready to receive bags into the central space.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A plastic bag holder 10 is shown in FIG. 1 in the closed state, in which the main body portion 12 generally presents an essentially toroidal enclosure having a small section, referred to as an enclosure opening or gap 14 , opening to provide access through the enclosure body portion 12 to a central opening 16 . The enclosure opening 14 has a retractable spring clip 30 , that will be described in greater detail below, that completes the toroidal enclosure at the enclosure opening 14 .
The main body portion 12 itself is in the shape of a slightly deformed toroid including a handle section 18 , preferably made of a cushioning material to provide comfort in holding when holder 10 is supporting a heavy weight, and an oppositely disposed bag engagement section 24 , which is ideally disposed at the horizontal position directly under the middle of the handle section 18 . The bag engagement section 18 comprises a rounded trough into which a loosely held bag handle would be naturally guided by the force of gravity acting on the items held in the bag. Thus, the bag engagement point on the main body 12 is inhibited from shifting as the bag and holder are transported.
The handle section 18 is connected to a portion of the main body 12 that is relatively linear, and which together with the handle section 18 provides for a comfortable hold by the user, irrespective of the amount of weight in the bags on the bag holder.
The handle portion preferably comprises a “soft” material, such as thermoplastic elastomer, and is firmly attached to the main body 12 by gluing or other appropriate means. As will be described below, the handle section comprises two halves, a right and a left half, which are joined to each other with the main body portion halves when the bag holder is constructed. The apertures 19 will be used to provide the connection of the two halves. The handle portion 18 includes a molded hand holdable shape, when the two halves thereof have been joined together, to present a plurality of finger grooves 20 separated by ridges 22 .
The top portion of the main body 22 includes an outwardly facing orifice 40 adjacent to the portion including clip 30 , the orifice having therein a depressible button release 42 , which includes an actuation mechanism that is described in greater detail below, to open and close the holder by pivoting the clip 30 about an axle 32 by which the clip 30 is held in place within the holder 10 .
The clip 30 is shaped and configured and is held in the closed position so as to close off the enclosure opening 14 , and so to present a complete enclosure for retaining the bag handles within the bag holder 10 . That is, there is no gap present in the enclosure provided by bag holder 10 through which bag handles may escape due to pulling forces or other phenomena. This is an important feature of the invention that provides the assurance that all bag handles will be retained when the bag holder 10 and bags have been placed on a surface for later pickup as a group.
Referring now to FIGS. 1 and 2 , the connection mechanism for connecting the two halves 12 a and 12 b of the bag holder main body 12 , the two halves 12 a , 12 b are essentially identical mirror images of each other except for the means to connect one half to the other. As seen in the cross-sectional view of FIG. 2 , one half 12 a , has an aperture 19 for receiving a prong 50 that is integrally attached to the other half 12 b . The aperture includes an inwardly extending wall 52 that terminates in an angled detent 54 . As can be seen in FIG. 1 , there are a plurality of these connections, one each at the apertures 19 , which are preferably distributed around the main body 12 , so as to retain the two halves to each other and also to retain the other movable elements, for example clip 30 and button release 42 , in place within the main body 12 .
The other half 12 b of the main body 12 also includes a corresponding detent 56 on the prong 50 , which when the two halves 12 a , 12 b are snapped together, will cooperate, as shown, to hold the two opposed walls of each half in a connected engagement. Although it may be possible to open the two halves, for example, with a special tool that can bend back the detent 56 and 10 release the engagement of each detent pair 54 , 56 , it should not be easy for an idle, curious or malicious person to disengage the detents so as to open the main body into its constituent two halves.
Referring now to FIG. 3 , the detail of the clip 30 and the mechanism for operation of the button release 42 will be described. Both the moving parts, that is clip 30 and button release 42 , are integral elements, that is, not split into halves such as the two main body halves 12 a , 12 b . The clip 30 is pivotable about and axle 32 , that may also comprise a detent combination 54 , 56 of FIG. 2 , but more preferably comprises a screw that engages an enclosed inwardly extending screw threaded plastic button (not shown) disposed on the inner wall of the opposite main body half 12 b . The axle 32 extends through a hole (not shown) in a tab, integrally attached to clip 30 , that permits pivoting of the clip 30 thereabout while simultaneously avoiding contact with the end curved walls 12 c , 12 d of the main body 12 . The tab extends into the inner recesses of the main body 12 through a slot 36 that is formed in the end walls 12 c , 12 d of the main body 12 , but also extends for a short distance along the outer wall portion. Preferably, the outer wall portion of the slot 36 extends to a point 37 directly adjacent the base of orifice 40 where it attaches to the main body 12 .
Tab 34 may be a flat portion that provides sufficient structural integrity as to be able to withstand a great amount of pressure from external forces without detaching. A metal pin or, preferably, a screw 32 , may also assist in inhibiting the detachment of the tab 34 from the main body 12 .
The clip 30 further includes a hook attachment 38 , including a detent 39 , for attaching the clip 30 to the opposed end of the main body 12 . A corresponding protrusion 21 , disposed in the inner surface of the opposed end walls 12 e , 12 f , provides for a secure connection to the clip 30 as shown in FIG. 1 , which connection can only be disengaged by depression of the release button 42 .
The release button releasably engages the end of the tab 34 inside of the main body 12 at an extension having a tab portion furthest from the clip 30 and on the opposite side of axle 32 . That extension portion (not shown) acts as a lever that upon depression by the release button 42 , causes the tab 34 and the clip 30 to pivot about axle 32 . Ideally, the initial disengagement of the hook 39 from the protrusion 21 is in the outward direction, and thus clears the protrusion when it is pivoted. Additionally, an appropriate mechanism (not shown) within the release button assembly acts to block the pivot action of clip 30 unless the release button 42 is depressed. The release button assembly includes a spring (not shown) that biases the release button 42 in the position shown in FIG. 1 , that is, in the position where the clip 30 is engaged with the other end of the main body 12 , and the wall 31 of clip 30 is flush with the end walls 12 e , 12 f.
The materials utilized for the main body portion 12 , the clip 30 and button 42 , are hard plastics, such as ABS or Derlin, which retain their integrity. As described above, the handle portion 18 providing for a more comfortable handle to the shopper comprises a different material, such as thermoplastic elastomer or polyurethane rubber. The axle 32 may be metallic, such as steel, and the spring (not shown) may also be made of spring steel, which can retain its elasticity for a great number of uses.
Assembly of the bag holder 10 proceeds in a very simple and straight forward manner. The spring and other movable parts are placed into one main body half, either 12 a or 12 b , and the second half is snapped into place by aligning the prongs 50 with apertures 19 , going around the complete body 12 to ensure that each of the detent pairs 54 , 56 engage each other and lock the main body into a connected unitary piece. Then the screw 34 is inserted into the aperture adjacent the orifice 40 and screwed into the opposing button, completing the assembly procedure. Testing of the operation by depressing the release button 42 provides an assurance of workability of the bag holder 10 .
To use the bag holder 10 , the shopper brings the bag holder on a shopping expedition, conveniently storing the bag holder in a coat pocket, purse or glove compartment of a vehicle. After proceeding through the checkout counter, the shopper uses the bag holder 10 by depressing the release button 42 , thereby opening up the enclosure opening 14 by retracting the clip 30 , and placing the bag handles into the enclosure 16 by inserting the open end of the main body 12 through both handles of each bag.
Although the most beneficial use of the bag holder 10 is with the ubiquitous plastic shopping bags, all types of bags, with or without protruding handles, may be held by the bag holder of this invention. In any case, one or more bags, of the same or of different types, may be retained within the enclosure 16 , and the shopper then lifts the bags together in one bunch by grasping the handle section 18 and carrying the bags to a vehicle or to the shopper's ultimate destination. If placed on the floor or in the trunk of the vehicle, the bag holder will retain the bags in control of the bag holder, so that when reaching the destination, the shopper need only lift the bag holder 10 , which will also pickup all of the bags that were resting on the floor or the trunk, without necessitating to ensure that each bag handle is being held.
With reference to FIG. 4 , an alternative embodiment of the clip is shown. Rather than a pivotable clip 30 that pivots about an axis 32 , described above, the clip 132 can span the gap 14 between the ends 112 a and 112 b of the alternative embodiment of the holder 110 . An outwardly extending pin 120 , which is either connected to or integral with the clip 130 , extends through a slot 136 in the outer peripheral wall of the main enclosure body 112 .
To open the gap for insertion of bag handles into the gap 14 , the shopper merely retracts the pin 120 toward the right through the slot 136 , which also slides the clip 130 into the walls defining the body 112 . After the bags have been inserted, the shopper releases the pin 120 , which is biased in the direction of the arrow by a spring 132 so as to close the gap 14 , and thereby enclosing the bag handles within the enclosure of the bag holder 110 .
The clip 130 and the pin 120 may comprise metal or hard plastic, or one may be plastic and the other metal. The use of the bag holder 110 follows the steps of that of the holder 10 , except instead of a button release, there is a sliding clip release actuated by the shopper in pulling back the pin 132 with a thumb.
This invention is described and illustrated in several preferred embodiments but modification, alterations, substitutions and other changes may be contemplated for those having skill in the art. For example, rather than the attachment combination of the pairs of detents 54 , 56 , a screw attachment may be utilized at each aperture 19 . Although the release mechanism describes a button 42 that is easily depressed by a single hand motion, so as to leave the other hand free to add bags being retained by the holder 10 , a lever or pin can be used to retract the clip 30 from the opening 14 . Accordingly, the above disclosure and illustration are to be considered exemplary only, and not limiting, the invention being only limited by the following claims and equivalents thereof. | A bag holder including a main enclosure body for practically enclosing a space shaped and configured to hold bags by their handles, the space being essentially surrounded by the main enclosure body, the main enclosure body having two ends proximate to each other which are separated by a gap and a retractable clip member connected to a first one of the main enclosure body ends and being capable to extend to and engage the second end such that engagement of the clip with the second end completes the enclosure formed by the main enclosure body, wherein the clip member is selectively positioned by the user as to open or close the gap. A method of using the bag is also disclosed. | 1 |
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 60/533,989, filed on Dec. 30, 2003, which is incorporated herein by reference in its entirety. This application relates to U.S. patent application Ser. No. 10/072,212 entitled, “System for Architecture and Resource Specification and Methods to Compile the Specification onto Hardware,” filed on Feb. 7, 2002 by A. Nayak, et al., and U.S. patent application Ser. No. 09/770,541 entitled, “Method and Apparatus for Automatically Generating Hardware from Algorithms Described in MATLAB,” filed on Jan. 26, 2001, by P. Banerjee, et al.. now U.S. Pat. No. 7,000,213 B2.
FIELD OF THE INVENTION
This invention relates to electronic design automation tools, and specifically to a graphical user interface for compiling MATLAB programs into hardware specific RTL files.
BACKGROUND OF THE INVENTION
Designers of electronic systems frequently use high-level language systems to model designs before committing them to hardware designs. For example, a designer may use MATLAB™, from The MathWorks, Incorporated of Natick, Mass. (“MATLAB”). MATLAB is a high-level algorithmic language that facilitates efficient mathematical modeling of systems. Unlike other languages such as C, MATLAB is dynamically typed, meaning that formal declarations for variables and constants are unnecessary. Additionally, MATLAB is array-based, where variable dimensions are determined at run-time. These aspects of MATLAB, among others, facilitate efficient modeling because the designer is not burdened with storage requirements and data typing.
FIG. 1 illustrates the MATLAB design flow 100 . The MATLAB user, such as a designer, creates a mathematical model 110 of a design using floating-point number variables. This MATLAB model 110 may include several files: A MATLAB script file 130 where the model is expressed as an algorithm; a MATLAB function file 125 which includes various functions used by the script file; and a MATLAB coefficient file 120 , which may be used as inputs to the algorithm. After the user creates an initial MATLAB model 110 by preparing a script file, and if necessary, function and coefficient files, the user may then execute the script file using the MATLAB environment 135 . Upon executing the script file, the results may be displayed 140 . The designer can examine the results and then make appropriate changes to the model 110 by modifying one of the files that comprise the model, such as the coefficient file 120 or the script file 130 .
Dynamically typed, array-based languages such as MATLAB provide various efficiencies to the designer during the modeling stage allowing the designer to create mathematical models without the burden of defining variable size and shape for each variable used in the model. However, these same features create challenges during design synthesis. Synthesis generates a file that is implemented directly in hardware. Unlike the MATLAB model, this resulting hardware implementation may not contain variables of unknown size and shape.
For example, FIG. 2A illustrates the mapping of a MATLAB script file 208 to a synthesized hardware module 209 . The hardware module 209 has an input port 203 , and output port 207 and other elements that can be used to perform various functions, such as a gate array 205 . The script file 208 maps elements onto the hardware module 209 in order to synthesize the design. For example, the data inputs 202 in the script file 208 are mapped onto physical hardware inputs 203 , and data outputs 206 from the script file 208 are mapped onto physical hardware outputs 207 . Similarly, various functions and modules in the script file 208 , such as fir16tap 204 , map to resources 205 in the hardware module 209 .
So that the correct number of hardware elements such as registers, data lines, and storage devices is allocated for each variable in the MATLAB model, the size and shape of variables are determined in advance of implementing any synthesized model in hardware. The number of inputs and outputs required by the MATLAB model determines the number of physical inputs and outputs allocated in the hardware implementation. Likewise, variables in the MATLAB script file require particular allocations of size and shape depending upon their use in the MATLAB model, which is determined prior to implementation in hardware.
As discussed above, MATLAB does not require designers to define the size and shape of the variables. In order to obtain a hardware implementation of the MATLAB model, the size and shape of all undeclared variables is determined automatically. In some instances, the designer may override the automatic size and shape determination by specifying a size or shape for a particular variable. Additionally, other parameters related to variables, such as loop indices, initial and final values, may also be either automatically determined or manually specified by the designer. Presenting this information to the designer and allowing the designer to manually specify selected attributes and parameters in a clear and efficient manner is difficult.
The designer requires an interactive system to review and customize variables types, sizes and dimensions. The system should automatically present the design in a manner that represents the algorithm being modeled, allowing the designer to compare and verify the typed- and dimensioned-design, for example a design that can be implemented in hardware, against the MATLAB model to determine whether the variable sizes, types, and dimensions are appropriate. The designer should also be able to modify the variable types, sizes, and dimensions and compare the results.
SUMMARY OF THE INVENTION
The present invention provides a visual representation of the design in a manner that allows the designer to more easily understand the algorithm being modeled. The designer can also modify the type, size and dimensions of variables from dialog boxes. The system allows the designer to efficiently compare and verify a fixed-point design versus the MATLAB design. The designer may then make further changes to the design, or synthesize the design into a register transfer level (“RTL”) file.
The user interface presents a display to the designer including multiple sections. The design flow section provides the designer with selectable icons for initiating various steps in the design process. For example, when the designer selects a project icon, a dialog box is presented to the designer for initiating the loading of a design file, such as a MATLAB model. The selection of an analyze icon initiates analysis of the loaded design file, including the process of determining the shape and size of variables in the design file. Selecting the verify icon begins the process of simulating the design and presenting the simulation results to the designer. By selecting a synthesize icon, the designer initiates a process of creating an RTL file from the simulated design.
After the analysis of the design file is complete, the project explorer section displays a hierarchical representation of the design file. The hierarchical representation includes several levels of design file elements. On the first level, the displayed elements are grouped in two three expandable subgroups, an analyzed design subgroup, an external dependency subgroup, and an output file subgroup. Within the analyzed design subgroup, programmatic design file elements, such as variables, functions and loops, are displayed on a second hierarchical level according to their type. For example, all variables are displayed in the variable subgroup, each variable displayed separately on a third hierarchical level. Similarly, loop elements are displayed in the loop subgroup, each element displayed separately on a third hierarchical level.
Selecting an element in the project explorer provides additional features. For example, highlighting a variable in the project explorer caused the viewer to display an instance of that variable in the script file. By highlighting elements in the project explorer, dialog boxes may be displayed allowing the designer to modified attributes of the highlighted element such as size, shape, and dimension.
The user interface also includes other features the display the design and allow different methods of controlling the design process. For example, the command line section provides an interactive display for presenting the run-time messages of a design process and providing for manual entry of commands to control the process. Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate several embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is an illustration of the MATLAB design flow.
FIG. 2A is an example of mapping a script file onto a synthesized hardware module.
FIG. 2B is an illustration, according to one embodiment of the present invention, of a system for compiling a MATLAB program into an RTL model.
FIG. 2C is a flowchart illustrating the design flow for compiling a MATLAB model into an RTL file using one embodiment of the present invention.
FIG. 3A is an illustration, according to one embodiment of the present invention, of a graphical user interface to a system for compiling MATLAB into an RTL model.
FIG. 3B is a flowchart of the process for displaying a MATLAB model in the project explorer window according to one embodiment of the present invention.
FIG. 4 is an illustration of the graphical user interface of FIG. 3 , further depicting the relationship between a variable element in the project explorer pane and the script file in a second pane according to one embodiment of the present invention.
FIG. 5 is an illustration of the graphical user interface of FIG. 4 , further depicting the relationship between a loop element in the project explorer pane and the script file in a second pane according to one embodiment of the present invention.
FIG. 6 is an illustration of the design flow when a designer selects the Verify Fixed Point control according to one embodiment of the present invention.
FIG. 7 is an illustration of the properties dialog box for a variable according to one embodiment of the present invention.
FIG. 8 is an illustration of the properties dialog box for a fixed point variable according to one embodiment of the present invention.
FIG. 9 is an illustration of the properties dialog box for a multiply instruction according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention is now described more fully with reference to the accompanying figures, in which several embodiments of the invention are shown. The present invention may be embodied in many 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 invention to those skilled in the art.
In one embodiment of the present invention illustrated in FIG. 2B , the system accepts a floating-point design 110 from MATLAB 100 upon selection of the Project button 220 in the graphical user interface. The system organizes the floating-point design 110 into a project directory 225 . When the designer selects the Analyze button 230 , the system assigns type, size, and dimensions to the variables in the design and optionally stores the analyzed design in memory 235 . The system also determines external dependencies and creates one or more output files.
The designer can test the analyzed design and compare it to the floating-point design by selecting the Verify Fixed Point button 240 . This selection creates a fixed-point design 245 , invokes MATLAB application and displays the results 250 . The designer can modify attributes and the script file and re-run the comparison. When the designer is satisfied that the fixed-point model meets the design objectives, the system can synthesize the design into and RTL model 260 in response to the designer selecting the Synthesize button 255 .
FIG. 2C is a flowchart illustrating the design flow using one embodiment of the present invention to generate an RTL file from a MATLAB design. In MATLAB 100 , the designer creates 265 a MATLAB floating-point model, also called a design. The designer then executes and tests 270 the MATLAB design 10 to determine 273 whether the design objectives were met. If the design objectives are not met, the designer modifies 275 the MATLAB floating-point design 10 and re-tests 270 the design until the design objectives are met.
Once the design objectives of the MATLAB floating-point design 10 have been met, the MATLAB floating-point design 10 is analyzed and a fixed-point model is generated 277 by the system. The fixed-point model may now be tested and compared 280 to the floating-point model. The designer then determines 283 whether the fixed-point model meets the design objectives. If the fixed-point model does not meet the design objectives, the designer modifies 285 variable attributes such as precision and dimensions in order to meet the design objectives. Then the fixed-point model is analyzed 277 , tested and compared 280 to the floating-point model and the results are evaluated 283 again.
If the fixed-point model meets the design objectives, an RTL file is synthesized 290 . After synthesis, the RTL file may be verified and optimized 295 .
FIG. 3A illustrates a graphical user interface according to one embodiment of the present invention. The graphical user interface (“GUI”) includes several panes including a design flow pane 310 , a project explorer pane 320 , a script and report viewer 330 , and a lower pane 340 that includes tabs for a Tool Control Language (TCL) console 350 and a MATLAB console 360 .
The design flow pane 310 comprises controls for the various steps of the design process. For example, a designer can initiate a design session by selecting the Project button 220 . In response to selecting the Project button 220 , the system will open a file dialog box providing the designer with a selection of files to choose.
Once the selection of files has been made, the designer can initiate the analysis process by selecting the Analyze button 230 from the design flow pane 310 . The Analyze button 230 initiates the type and shape inferencing process where the system analyzes the script file variables and their use to determine the type and dimension of each of the variables. The system also performs other functions in response to the Analyze button 230 such as unrolling inferred loops, and determining which functions are used in the script file. Additionally, the system transforms floating-point numbers into a fixed-point representation. An example of the above inferencing and transform processes is set forth in U.S. patent application Ser. No. 09/770,541.
After the project has been analyzed, the designer can compare the analyzed project to the floating-point design by selecting the Verify Fixed Point button 240 . This selection results in an automatic invocation of MATLAB to analyze the fixed-point design. After completing the MATLAB analysis, the system will present the designer with the results of both the floating-point design and the fixed-point design. The designer can then compare the results from both designs.
When the designer is satisfied that the fixed-point design meets the design requirements for example, the designer can synthesize the design into an RTL model 260 by selecting the Synthesize button 255 . Other design flow processes may also be initiated by selecting controls from the design flow pane. For example, the designer may have a particular optimizer that modifies the RTL model for a particular target device. The control for initiating this process may be selected from design flow pane 310 . Similarly, a process for verifying the RTL model may also be selected from the design flow pane 310 . In this manner, the design flow pane 310 provides a single location for controls to initiate all the processes in the designer's design flow.
The project explorer pane 320 illustrates the design in an algorithmic fashion. For example, in this pane, all the variables and functions used in the script file are presented to a designer in a manner that represents the algorithm more intuitively than a script file. This pane will be discussed in greater detail below.
The script and report viewer 330 presents the section of particular files in response the designer's selection of various controls. In FIG. 3 , the script file for the design is shown in the script and report viewer 330 .
The lower part of the GUI contains the lower pane 340 . The lower pane runs along the bottom portion of the GUI window, under the design flow pane 310 , the project explorer pane 320 , and the script and report viewer 330 . The lower pane 340 contains multiple tabs that may be selected to present different views in the lower pane 340 . For example, the Tcl Console tab 350 displays the system's command line messages and commands. The MATLAB Console tab 360 likewise allows the designer to view the MATLAB command line messages and commands. Both of these console tabs allow the designer to enter commands directly on the command line for either the system or MATLAB, or other processes of the design flow that have a command line interface.
FIG. 3B is a flowchart illustrating the process that occurs to present the MATLAB design in the project explorer pane 320 . The process begins 110 with the MATLAB design. The system then determines 370 the file hierarchy by analyzing the design to identify common programmatic constructs, such as variables and functions, and grouping common constructs together. After determining the file hierarchy, the file is scanned 375 to identify loops. For each loop, the system identifies 380 the loop dependencies and attributes, such as indices, maximum and minimum iteration limits, inputs to the loop, outputs from the loop, and functions used within the loop. The design is then visually presented 385 in the project explorer pane 320 .
FIG. 4 illustrates some features of the project explorer pane 320 according to one embodiment of the present invention. The project explorer pane 320 presents the elements of the design in a hierarchical manner. The name of the design, “fir16tap” appears at the top of the pane. After the designer directs the system to analyze the design, other design elements appear below the file name. For example, in one embodiment all the variables used in the design appear in a “Variables” folder 420 ; loops 430 , branching instructions and conditional statements are presented on the same level as the Variables folder 420 , below the variables; below the loop 430 appears the various algorithmic functions used in the design.
Near the bottom of the project explorer pane 310 , two other elements are shown: the External Dependencies 440 and the Output Files folder 450 . The External Dependencies 440 element contains a list of those items used by the design that are not included in the script file itself. For example, the design may call a data file as input to the algorithm. The Output Files folder 450 contains files that include data such as the results of the execution of the algorithm.
The project explorer pane 320 provides the designer with the ability to quickly identify elements of the design, such as variables or loops. For example, highlighting a variable such as “NUMTAPS” 400 causes the system to locate the instance in the design where that variable is used, present the instance in the script and report viewer pane 330 , and highlight the instance 410 in the script and report viewer pane 330 . The designer is presented with a side-by-side visual representation of the use of the selected element in the design hierarchy and in the corresponding script file. In this manner, the designer can quickly locate and examine the instances of each element of the design. This form of visualization allows the designer to better understand the use of the element in the design.
FIG. 5 illustrates the use of the project explorer pane 320 to identify a loop structure 500 . Each element of the loop is presented in the project explorer window including the loop parameters, such as the loop index starting and ending values 520 . Selecting the loop instruction 430 causes the system to locate the instance of the loop in the design and present the instance 510 to the designer in the script and report viewer pane 330 .
FIG. 6 illustrates the process flow that occurs when the Verify Fixed Point control 316 is selected. The analyzed design 610 including the fixed-point design is executed 135 by the MATLAB interpreter. The results 620 are then presented to the designer along side the results 140 from the floating-point design. By presenting the results of the two models in this manner, the designer can efficiently compare the two designs to determine whether the fixed-point design meets the design objectives.
FIG. 7 illustrates an additional feature of the project explorer pane 320 . A designer can quickly view and modify information about elements of the design using the project explorer pane 320 , as opposed to having to rewrite the script file. For example, if a designer selects the NUMTAPS variable 400 , the designer may open the “Properties” dialog box 700 by actuating the right button on the mouse. The Properties dialog box 700 presents the designer with the variable attributes. The variable name 710 appears at the top of the Properties dialog box 700 . The instance path 720 indicating where the variable is used in the design is also shown.
Additionally, the Properties dialog box 700 present the designer with attributes assigned by the analysis process. For example, the “Shape” attribute 720 shows the dimensions of the variable. In this case, the variable is a 1×1 array. The designer can easily modify this dimension by entering a different dimension directly into the Properties dialog box 700 . Similarly, precision and type information are shown in the “Quantizer” section 730 . Note that the analysis process has assigned a length to this variable of five bytes 740 . This length can be increased or decreased to accommodate the design requirements by entering a new length directly into the Properties dialog box 700 .
This feature can be particularly useful after comparing the fixed-point design to the floating-point design. For example, after comparing the two designs, the designer may need to adjust the precision of a variable to provide for more bits of precision, or may want to reduce the precision to save space in the target device. FIG. 8 illustrates the Properties dialog box 700 for a variable with both integer and fractional components. This variable is an array of 1024 values as illustrated by the Shape attribute 810 and reflected in the “Columns” attribute 820 . The word length for this particular variable is presented by the “Word Length” attribute 740 as 17 bytes. “The Fractional Length” attribute 830 indicates that four of the 17 bytes are assigned to the fractional component of the value to be represented. If the designer needs to increase the precision of this value, the designer may enter a five or six directly into the Fractional Length attribute 830 section of the Properties dialog box 700 .
The designer may cause the system to display attributes of any element of the design through the project explorer 320 . For example, FIG. 9 illustrates a Properties dialog box 700 for a multiply operation 910 . In this case, the multiply operation 910 accepts an array as an input. Because the array consists of a number of discrete values that must be multiplied to complete the operation, an implied loop is created. In this manner, the first array values can be multiplied, then the next array values, and so on until all the discrete array values have been multiplied.
The attributes for the multiply operation are presented in the Properties dialog box 700 for this multiply operation 910 . Notably, an “Unroll” attribute 920 is presented. This attribute indicates how many times the implied loop of the multiply operation 910 will execute. For example, the multiply operation 910 can be performed by a single multiply function. Alternatively, two or more multiply functions can be performed in parallel to increase throughput, at the expense of requiring more target hardware. The Unroll attribute 920 allows the designer to control this design trade-off by specifying the amount of parallel processsing that will be implemented in the target design. The designer may modify the amount of parallel processing by simply entering a new value for the Unroll attribute 910 .
Having described embodiments of the Algorithmic and Dataflow Graphical Representation of MATLAB (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments of the invention disclosed that are within the scope and spirit of the invention as defined by the appended claims and equivalents. | The present invention relates to a graphical user interface for a system that compiles MATLAB models for synthesis into register transfer level code. The graphical user interface provides a visual representation of the design in a manner that allows the user to more easily understand the algorithm being modeled. From this interface, the user may also modify the type, size and dimensions of variables from dialog boxes. The system allows the user to efficiently compare and verify a fixed-point design versus the MATLAB design. The interface allows the user to then make further changes to the design, or synthesize the design into a register transfer level file. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of German Patent Application No. 103 57 933.8, filed on Dec. 11, 2003, the subject matter of which, in its entirety, is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a method and a device for restarting an internal combustion engine in a motor vehicle, in which the engine is to be temporarily switched off in specific driving operating states in order to save fuel and is to be automatically restarted when the driving mode is resumed, without the vehicle driver having to actuate the starter with his ignition key for this purpose.
BACKGROUND OF THE INVENTION
[0003] A device of the generic type and a method of the generic type for automatically starting an internal combustion engine are known from the European patent EP 10 63 424 B1. In this previously known device and the previously known method, the position of the brake pedal is sensed by means of suitable sensors. If the vehicle driver releases the brake pedal again as it leaves its actuator position, the internal combustion engine of the motor vehicle is automatically started if the brake pedal approaches its actuated home position. In comparison with other start/stop devices which are also previously known for internal combustion engines, this has the advantage that the vehicle driver senses the restarting of the internal combustion engine as significantly more spontaneous.
[0004] Taking the prior art described above as the starting point, the object of the invention is to specify a further improved solution with which the vehicle driver senses the start/stop device as even more pleasant and the acceptance of the start/stop device according to the invention is increased.
SUMMARY OF THE INVENTION
[0005] The solution is arrived at by means of a method and a device corresponding to the independent claims. Advantageous refinements of the invention are disclosed in the subclaims and in the exemplary embodiments.
[0006] The solution is obtained mainly with a brake pressure monitoring system and a means of evaluating the brake pressure with respect to its profile over time. The brake pressure gradient is evaluated when the brake pedal is released before the vehicle is restarted. If the absolute value of the negative brake pressure gradient when the brakes are released exceeds a threshold value, this upward transgression of the threshold value causes an electronic control system in the motor vehicle to restart the internal combustion engine in conjunction with a start/stop function. The advantage which is mainly achieved with this is that the brake pressure gradient precedes the point at which the brake pedal reaches its position of rest so that a vehicle driver can sense the restarting of the internal combustion engine to be much more spontaneous than in the prior art. With the solution according to the invention for restarting the internal combustion engine, a longer time period is available than with the start/stop function such as is known from the European patent EP 10 63 424 B1. As a result, in contrast to the previously known prior art it becomes to possible to initiate the restarting of the internal combustion engine at such an early time that when the vehicle driver wishes to drive off again the engine is already completely started again. With the start/stop function from the prior art, only the time period which the vehicle driver requires changes from the brake pedal to the accelerator pedal is available for restarting the internal combustion engine. This time period is generally too short, giving rise to a situation in which it is necessary to take measures to ensure that the vehicle cannot start moving before the internal combustion engine has started. This has previously led to considerable acceptance problems of start/stop functions in motor vehicles.
[0007] A further advantage of the invention is the possibility of carrying out the restarting of the internal combustion engine in a way which is adapted to the respective vehicle driver. For this purpose, it is possible to include, for example, the driver type classification in the detection as to whether the brake pressure gradient has exceeded a predefined threshold value, said classification having been introduced in the modern motor vehicle for example from adaptive automatic transmissions. The adaptation to the respective vehicle driver is however also already supported by the brake pressure gradient itself since the brake pressure gradient is dependent on how quickly the vehicle driver releases the brake pedal. This also has the advantage that the restarting of the internal combustion engine can be adapted in a way which is appropriate to the situation. If the vehicle driver releases the brake pedal quickly, the internal combustion engine starts earlier, while if the vehicle driver relieves the brake pedal only slowly, the brake pressure gradient tends to remain low so that the internal combustion engine only needs to started again when the brake pressure itself drops below a threshold value.
[0008] In another advantageous exemplary embodiment, the vehicle driver can select whether or not he wishes to make use of the automatic start/stop function. For this purpose, he has the possibility of switching the function for automatically starting the internal combustion engine on and off by means of a switching means.
[0009] In another advantageous exemplary embodiment, additional sensors can also be included in the restarting detection operation, these sensors preventing the restarting of the internal combustion engine being carried out. This may be necessary, for example, for safety reasons if the engine hood of the motor vehicle is opened, the vehicle is involved in an accident or if the residual charge of the starter battery is no longer sufficient to be able to restart the internal combustion engine for a further number of times.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Without restricting the general applicability, exemplary embodiments of the invention are explained in more detail below with reference to figures, of which:
[0011] FIG. 1 is an overview diagram of the interaction between various components for a start/stop function in a motor vehicle;
[0012] FIG. 2 shows a functional framework for the determining of the brake pressure gradient;
[0013] FIG. 3 shows a functional framework with vehicle type classification means;
[0014] FIG. 4 shows a functional framework for preventing starting;
[0015] FIG. 5 shows the profile with respect to time of the brake pressure and brake pressure gradient.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The manner of operation of a method for automatically starting an internal combustion engine is explained in more detail below with reference to FIG. 1 . An internal combustion engine 1 is started in a manner known per se with an electric starter 2 . Alternative starting possibilities/starters are: starter generators integrated onto the crankshaft (ISG) or by means of the belt drive (RSG) and electric machines in hybrid vehicles, for example an electric machine which is connected to the crankshaft. The starting sequence for the electric starter 2 is transmitted by a control device 3 via a communication connection 4 . A CAN bus system for communicating between various electrical and electronic units in the motor vehicle is preferably used in the motor vehicle. Further units which are important for the invention are connected to the CAN bus 5 . As a result, the control device 3 is connected to a brake pressure sensor 6 , to the master brake switch 7 , to the starter 2 and to the hydraulic pump 8 of a hydraulic assembly 9 . The hydraulic pump 8 and hydraulic assembly 9 supply and distribute the brake pressure to the wheel brakes 10 of the motor vehicle. The pressure which is to be used to activate the wheel brakes is predefined with a brake pressure regulator 11 , usually comprising the brake pedal 12 , a brake pressure booster 13 and a tandem master brake cylinder 14 . The brake pressure is predefined here by a vehicle driver by actuating the brake pedal 12 . The master brake switch 7 monitors and detects whether the brake pedal 12 has been actuated. If the brake pedal 12 has been actuated, the master brake switch 7 transmits a corresponding CAN signal to the control device 3 . Corresponding to the predefined value for the brake pressure, the brake pressure is set at the wheel brakes by means of the control device 3 by actuating the hydraulic pump 8 . For this purpose, a permanent brake pressure monitoring means and a corresponding brake pressure control means are implemented in the control device 3 . The monitoring of the brake pressure is carried out here by means of the brake pressure sensor 6 which taps the brake pressure in the hydraulic lines of the brake system at a suitable point.
[0017] To this extent, as described above, the invention has recourse to motor vehicle systems which are known per se. The invention then consists in determining a brake pressure gradient from the brake pressure monitoring means. This chronological brake pressure gradient is compared, in terms of its absolute value, with a threshold value, and a decision criterion as to when a starting sequence in the form of a start bit is to be transmitted to the starter 2 of the internal combustion engine by the control device 3 is acquired from it so that the internal combustion engine is automatically started in this way. In practical terms, this means that the system monitors how quickly a vehicle driver takes his foot off the brake pedal 12 . If the vehicle driver takes his foot off sufficiently quickly from the brake pedal 12 , the brake pressure will be reduced with a correspondingly large brake pressure gradient. By predefining a threshold value with which the brake pressure gradient is compared, a suitable criterion can be established as to when the internal combustion engine is to be started. Since the brake pressure gradient precedes the point at which the brake pedal reaches the non-actuated position of rest, in comparison with conventional methods more time is gained for automatically starting the internal combustion engine. The necessary evaluation algorithms are implemented here as application programs in the electronic control device 3 .
[0018] A functional diagram of the application program referred to above is shown in FIG. 2 . The brake pressure signal which is transmitted by the pressure sensor 6 to the control device 3 is subjected to a derivation 20 over time by means of a data processing system and the brake pressure gradient which results from this is checked in terms of its sign and its absolute value. If the brake pressure gradient is negative, that is to say if the brake pressure decreases, the absolute value of this decrease is fed to a comparison operation 21 in which a comparison is carried to determine whether or not the absolute value of the decrease in the brake pressure exceeds a predefined threshold value 22 . If the absolute value of the brake pressure gradient exceeds the predefined threshold value, a starting signal is generated from the gradient evaluation 23 and passed on. The starting signal is preferably fed, in the form of a starter bit, to the CAN bus of the communications network in the vehicle. In the exemplary embodiment in FIG. 2 , OR operations are performed on the starting signal from the gradient evaluation 23 with respect to further redundant possible starting conditions. Further conditions for the generation of a starting signal are that the brake pressure itself drops to below a reference value 24 . For this purpose, the brake pressure is compared using a comparison operation 25 with the threshold value for the brake pressure. If the brake pressure drops below the predefined threshold value, a starting signal is also generated. A third possible way of automatically generating a starting signal is to use the signal of the master brake switch 7 . If the brake pedal reaches its non-actuated position of rest, this is detected by means of the master brake switch 7 and a starting signal is triggered in the control device 3 . The three possible conditions for the triggering of a starting signal by means of the master brake switch 7 , by means of the gradient evaluation 23 and by means of the brake pressure comparison 25 are subjected to an OR operation 26 with one another so that basically a starting signal can be fed to the CAN bus if at least one of the three previously mentioned conditions is fulfilled.
[0019] The result from the signal comparison of the OR operation 26 , the automatic starting of the internal combustion engine by means of brake pressure monitoring and gradient evaluation, can also be switched off by the vehicle driver. By activating the switching element 27 , which is provided as an operator control element in the passenger compartment of the vehicle, the vehicle driver can decide whether or not he wishes to make use of the brake pressure monitoring. Depending on the position of the switching element 27 , the brake pressure monitoring is used for the automatic starting of the combustion engine, or not. If the brake pressure monitoring is switched off, it is nevertheless possible for automatic starting of the internal combustion engine to take place, the signal of the master brake switch merely being evaluated in the manner known per se. The internal combustion engine starts when the brake pedal moves back out of its actuated position into its non-actuated position of rest. The switching on and off of the brake pressure monitoring for the generation of a starting signal is preferably implemented by software using a logic switching means 28 . The logic switching means 28 is composed here of a logic program interrogation, which signal is ultimately to be used for starting the internal combustion engine of the function of the position of the on/off switch 27 . Depending on the position of the switch 27 , either only the signal from the master brake cylinder is to be used or the signal from the OR operation 26 , which contains the brake pressure monitoring, is to be used for starting the internal combustion engine.
[0020] The gradient evaluation 23 which has already been described in conjunction with FIG. 2 can also be carried out in an adaptive way. An example for a gradient evaluation 23 which is carried out in an adaptive way is restricted in the function diagram in FIG. 3 . The evaluation of the brake pressure or of the brake pressure signal from the pressure sensor 6 is carried out in a way analogous to that in FIG. 2 . A brake pressure gradient is formed and the brake pressure gradient is evaluated in terms of sign and absolute value. In the case of a negative sign, the absolute value of the brake pressure gradient is fed to a comparison operation 21 in which this absolute value is compared with a reference value. However, in contrast to the exemplary embodiment in FIG. 2 , this reference value 30 can now be influenced and changed by means of the driver type classification. Driver type classifications are known from adaptive automatic transmissions or from control systems for adaptive automatic transmissions. They classify the driver in terms of his sporty inclinations with a value of, for example, 0 to 255. These driver type classifications which are known per se are then also used in the invention in order to generate a starting signal from the gradient evaluation 23 . The reference value with which the absolute value of the brake pressure gradient is compared is formed here from the multiple of a basic constant 31 , this basic constant 31 being multiplied by the numerical value of the driver type classification and this product forming the reference value 30 which is included in the comparison operation 21 . If the absolute value of the brake pressure gradient exceeds the reference value which is obtained in this way, a starting signal is generated from the gradient evaluation 23 . Sporty drivers will generally take their foot off the brake pedal more quickly so that with such drivers the absolute values of the brake pressure gradient are larger than for less sporty drivers. A larger reference value is therefore recommended for sporty drivers. Since otherwise misinterpretations as a result of the gradient evaluation may occur from the point of view of a sporty driver.
[0021] FIG. 4 refers to a safety aspect. Under certain selected conditions, the internal combustion engine should be prevented from starting by means of an automatic method. Particularly selected methods in which it is necessary to prevent the internal combustion engines starting automatically are an opened engine hood, an accident in which the vehicle is involved, or if the residual charge in the starter battery is no longer sufficient to start the internal combustion engine a number of times. In these cases, a starter bit which is possibly present and which has been generated from one of the preceding processes is negated and an automatic starting process is thus prevented.
[0022] The presence of an accident is generally detected using a crash sensor. The opened engine hood can also be detected with a suitable sensor and the monitoring of the starter battery with respect to a battery charge limit can also be carried out with a charge reserve monitoring system which is known per se.
[0023] FIG. 5 is also concerned with the method of operation of the invention. Three time diagrams which are referred to a common time base are illustrated. The profile of the brake pressure gradient, the profile over time of the brake pressure itself and the transmission of the starter bit to the communication bus of the vehicle are illustrated. At the time T 1 , the vehicle driver releases the brake pedal. Starting from the time T 1 , the braking torque at the wheel brakes will decrease and ultimately disappear entirely. The brake pressure and thus the braking torque has been reduced to zero at the time T 2 . In the method for automatically starting an internal combustion engine such as is known from the prior art, the starting of the internal combustion engine would be initiated at the time T 2 . However, the gradient evaluation of the brake pressure permits the internal combustion engine to be started significantly earlier. A brake pressure gradient which can be evaluated is in fact already present at the time T 1 when the driver begins to take his foot off the brake pedal. A threshold value evaluation of the brake pressure gradient can thus be used to start an internal combustion engine. As a result, the internal combustion engine can be started by evaluating the brake pressure gradient signal very close to the time T 1 at which the vehicle driver wishes to release the brake. In contrast with the prior art, the invention thus provides a time interval ?t between the times T 3 in which interval the brake pressure gradient exceeds a predefined threshold value d/dtM ref up to the time when the brake pressure drops to the value zero at the time T 2 , and said interval can additionally be used for automatic starting of the internal combustion engine. The method according to the invention has therefore provided a time advantage in comparison with the methods known from the prior art.
[0024] It will be appreciated that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | The invention relates to a method and a device for automatically starting an internal combustion engine having a brake pressure monitoring system and a means of evaluating the brake pressure with respect to its profile over time. The brake pressure gradient is evaluated when the brake pedal is released before the vehicle is restarted. If the absolute value of the negative brake pressure gradient when the brakes are released exceeds a threshold value, this upward transgression of the threshold value causes an electronic control system in the motor vehicle to restart the internal combustion engine in conjunction with a start/stop function. The main advantage which is achieved in this way is that the brake pressure gradient precedes the point at which the brake pressure reaches its position of rest so that a vehicle driver can sense the restarting of the internal combustion engine to be more spontaneous than in the prior art. With the solution according to the invention for restarting the internal combustion engine a longer period of time is available than with previously known solutions. | 5 |
BACKGROUND
(a) Field of the Invention
The present invention relates to a transfer apparatus, and particularly to a transfer apparatus for transferring a large size glass substrate.
(b) Description of Related Art
In general, a transfer system or apparatus utilizes a conveyor apparatus to move a transfer object by placing the transfer object onto a conveyor which works in conjunction with an operating roller connected to an operating motor.
The conventional conveyor system uses the operating motor to provide power to move the transfer object and a chain, a gear, or a belt for the purpose of power transfer. Disadvantageously, the belt or chain may break or wear out causing maintenance problems and manufacturing delay.
Furthermore, since dust is generated due to the driving of a motor, the motor is arranged apart from the remainder of the conveyor system so as not to affect the transfer objects, such as semiconductor devices or liquid crystal displays (“LCDs”), in which cleanliness is an important issue. Therefore, because the motor is isolated from the place where the object is transferred, the operation is made more difficult, the system is more complicated, and the cost is increased.
Dust problems also arise with the use of gears. For a conventional apparatus, since one motor should drive a plurality of driving axes, a medium for transferring power, such as a gear, is required between each driving axes, which causes the dust problems indicated above.
If a motor and a conveyor belt are used, a noise problem also arises. The noise from machinery disturbs the operator or administrator, which decreases operation efficiency.
A transfer system or apparatus can be utilized to transfer glass substrates used in manufacturing liquid crystal displays (“LCDs”). An LCD is one of the most popular flat panel displays, which includes two panels provided with two kinds of electrodes generating an electric field and a liquid crystal layer interposed therebetween. The LCD displays images by controlling light transmittance, and the control of the light transmittance is performed by applying voltages to the electrodes to generate electric fields which change the arrangement of liquid crystal molecules.
The panels of an LCD can be transferred to processing devices used in the manufacturing process by using the transfer system. Conventionally, a plurality of glass substrates are transferred to a processing device using a cassette, a stocker, and an indexer. However, as glass substrates are getting larger, the conventional transfer system using the cassette, stocker, and indexer becomes harder to use and manage due to inflexibility and unwieldiness.
Various conventional transfer apparatuses such as conveyors, robots, stockers, AGVs (automatic guided vehicles), etc. have been enlarged in order to accommodate enlarged glass substrates. However, disadvantages remain with conventional systems and apparatus, such as generation of static electricity, decreased yield accompanied by contamination, and generation of cracks due to the contact between the glass substrate and the conveyor belt. Thus, there is a need in the art for a transfer apparatus that is flexible and clean and that transports objects securely without damage.
SUMMARY
The present invention provides an advantageous apparatus for transferring fragile objects, such as glass substrates used in the manufacture of LCDs, in which cleanliness and secure transport are of high concern. A plurality of air nozzles are used to transport glass substrates without making direct contact between the air nozzle structure and the substrate, thereby allowing for clean and secure transport of the substrate.
According to one embodiment of the present invention, a transfer apparatus is provided, including a panel, and a plurality of air nozzles operably coupled to the panel. The plurality of air nozzles can inject air to hold a transfer object in place above the plurality of air nozzles without the plurality of air nozzles making contact with the transfer object.
According to another embodiment of the present invention, another transfer apparatus is provided, including a connection body operably coupled to a guide line. A panel section is operably coupled to the connection body, and a plurality of air nozzles is operably coupled to the panel section. The plurality of air nozzles can inject air to hold a transfer object in place without the plurality of air nozzles making contact with the transfer object.
According to yet another embodiment of the present invention, another transfer apparatus is provided, including a panel, and a plurality of air nozzles operably coupled to the panel, wherein the plurality of air nozzles inject air while simultaneously providing suction to hold a transfer object in place without the plurality of air nozzles making contact with the transfer object.
Advantageously, the present invention allows for the secure and clean transport of glass substrates and other fragile objects, resulting in higher yields with less damage and contamination. The present invention also is advantageous to reduce noise while increasing transfer speed.
These and other features and advantages of the present invention will be more readily apparent from the detailed description of the embodiments set forth below taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a transfer apparatus according to a first embodiment of the present invention showing a state in which a glass substrate is stopped;
FIG. 2 is a sectional view of the transfer apparatus shown in FIG. 1 taken along the line II–II′;
FIG. 3 is a perspective view of a transfer apparatus according to the first embodiment of the present invention showing a state in which a glass substrate is being transferred;
FIG. 4 is a sectional view of the transfer apparatus shown in FIG. 3 taken along the line IV–IV′;
FIG. 5 is a perspective view of a transfer apparatus according to the first embodiment of the present invention showing a state in which a glass substrate is stopped at a branch point;
FIGS. 6A and 6B are sectional views of the transfer apparatus shown in FIG. 5 taken along the lines VIA–VIA′ and VIB–VIB′, respectively;
FIG. 7 is a perspective view of a transfer apparatus according to the first embodiment of the present invention showing a state in which a glass substrate is moved from a branch point to a branch direction;
FIG. 8 is a sectional view of the transfer apparatus shown in FIG. 7 taken along the lines VIII–VIII′;
FIG. 9 is a perspective view of a transfer apparatus according to a second embodiment of the present invention;
FIG. 10 is a lateral view of the transfer apparatus shown in FIG. 9 ;
FIG. 11 is a perspective view of a transfer apparatus according to a third embodiment of the present invention;
FIG. 12 is a lateral view of the transfer apparatus shown in FIG. 11 ; and
FIG. 13 is a perspective view of an embodiment of an air transfer groove formed inside an air nozzle.
Use of the same reference symbols in different figures indicates similar or identical items. It is further noted that the drawings may not be drawn to scale.
DETAILED DESCRIPTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
In the figures, the thickness of layers and regions are exaggerated for clarity. Like numerals refer to like elements throughout. It will be understood that when an element such as a layer, region, or substrate is referred to as being “on” another element, the element can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.
A transfer apparatus according to preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
FIGS. 1–8 and 13 illustrate a transfer apparatus according to a first embodiment of the present invention. FIG. 1 is a perspective view of an example of the transfer apparatus showing a state in which a glass substrate is stopped. FIG. 2 is a sectional view of the transfer apparatus shown in FIG. 1 taken along the line II–II′, FIG. 3 is a perspective view of an example of the transfer apparatus showing a state in which the glass substrate is being transferred. FIG. 4 is a sectional view of the transfer apparatus shown in FIG. 3 taken along the line IV–IV′. FIG. 5 is a perspective view of an example of the transfer apparatus showing a state in which the glass substrate is stopped at a branch point. FIGS. 6A and 6B are sectional views of the transfer apparatus shown in FIG. 5 taken along the lines VIA–VIA′ and VIB–VIB′, respectively. FIG. 7 is a perspective view of an example of the transfer apparatus showing a state in which the glass substrate is transferred from a branch point to a branch direction. FIG. 8 is a sectional view of the transfer apparatus shown in FIG. 7 taken along the lines VIII–VIII′. FIG. 13 illustrates a perspective view of an embodiment of an air transfer groove formed inside an air nozzle.
Referring now to FIGS. 1 and 2 , a transfer apparatus includes a support panel 10 and a plurality of air nozzles 20 that are formed on the support panel 10 for transferring a transfer object 30 , in one example a glass substrate. FIGS. 1 and 2 illustrate transfer object 30 at a rest position.
The support panel 10 is arranged along the transfer direction of transfer object 30 . In other words, support panel 10 is installed along desired transfer directions for the transfer object, for example along a transfer direction A of transfer object 30 and also along a branch direction B ( FIGS. 7 and 8 ) in which transfer object 30 is carried after being branched off at a branch point of support panel 10 . The plurality of air nozzles 20 formed on support panel 10 are arranged along direct transfer direction A and also along branch direction B. When transfer object 30 is carried, air nozzles 20 are placed under the transfer object 30 .
As can be seen in FIG. 2 , air nozzles 20 are in a perpendicular configuration such that air nozzles 20 inject air in a perpendicular direction relative to transfer object 30 and support panel 10 . The physical structure of air nozzles 20 and transfer object 30 do not come into contact with one another. Instead, air nozzles 20 are placed to maintain a prescribed distance between transfer object 30 and each of the plurality of air nozzles 20 . In order to accomplish this, the plurality of air nozzles 20 fix the position of transfer object 30 by injecting air and forming a vacuum status inside each of the plurality of air nozzles 20 to prevent transfer object 30 from straying by the injection of air. In other words, at each air nozzle, there is simultaneous air injection impinging on the surface of the transfer object and a vacuum or suction effect, similar to a whirlpool's center, and thus the air injection “sticks” to the transfer object, thereby stabilizing the position of the transfer object.
FIG. 13 is a perspective view of a section of an air transfer groove 21 formed inside an air nozzle 20 to form a vacuum status inside each of the plurality of air nozzles 20 . Air transfer groove 21 can be formed to have various forms for creating simultaneous air injection and suction. In one example, air transfer groove 21 can be formed to be slanted or spiral in shape.
Referring now to FIGS. 3 and 4 , an example is illustrated of transfer object 30 being moved or transferred in direction A. The plurality of air nozzles 20 are formed such that inclination of air nozzles 20 relative to the transfer direction can be controlled. FIG. 4 illustrates air nozzles 20 making a specified angle θ with reference to the transfer direction of transfer object 30 , in one example direction A.
Control over the inclination of air nozzles 20 in conjunction with pressure of the air injection directs the transfer or movement of transfer object 30 . If transfer direction A of transfer object 30 and the inclination of air nozzle 20 make up an angle over 0 degrees and under 90 degrees in an up and down direction, transfer object 30 would be transferred forward. If transfer direction A of transfer object 30 and the inclination of air nozzle 20 make up an angle over 90 degrees and under 180 degrees in an up and down direction, transfer object 30 would be transferred backward. Referring to FIG. 2 , if transfer direction A of transfer object 30 and the inclination of air nozzle 20 make up an angle of 90 degrees, transfer object 30 would be stopped. Transfer speed of transfer object 30 can be controlled by controlling pressure and direction of the air injected via air nozzles 20 .
Advantageously, since the plurality of air nozzles 20 and transfer object 30 are not in contact with one another but maintain a prescribed distance with each other, the transfer speed is enhanced, no noise is generated, and the transfer object is transferred without damage. Distance between air nozzles 20 and transfer object 30 is preferably between about 10 μm and about 30 μm.
As noted previously, the plurality of air nozzles 20 are formed to be able to make a specified angle in up and down or back and forth directions with reference to the transfer direction of transfer object 30 . Referring now to FIGS. 5 , 6 a, and 6 b, a certain set of air nozzles 20 ′ can form a perpendicular or 90 degree angle with reference to the transfer direction of transfer object 30 when stopping and/or changing the direction of transfer object 30 at a branch point in support panel 10 . Thus, some air nozzles may operate independently from one another so as to be inclined at different angles or operate with different air injection pressures in order to stop and/or change the direction of transfer object 30 during transport.
As shown in FIGS. 7 and 8 , when transfer object 30 arrives at a branch point and is stopped, the plurality of air nozzles 20 ′ switch their inclination to branch direction B to direct transfer object 30 along the branch support panel 10 in branch direction B. Transfer object 30 can be transferred to branch direction B by switching the direction of air nozzles 20 ′ to make an angle over 0 degrees and under 90 degrees in left and right directions with reference to the transfer direction of transfer object 30 .
The operation of the transfer apparatus according to an embodiment of the present invention having a structure as described above will now be described.
First, as shown in FIGS. 1 and 2 , the plurality of air nozzles 20 engage transfer object 30 without contacting transfer object 30 with the physical structure of air nozzles 20 by injecting air. Since the plurality of air nozzles 20 are inclined 90 degrees, transfer object 30 is not moving or being transferred and is instead in a rest position.
Next, as shown in FIGS. 3 and 4 , the plurality of air nozzles 20 are inclined to have a specified angle in up and down directions with reference to direct transfer direction A of transfer object 30 . The inclination of air nozzles 20 also directs the air injection from the plurality of air nozzles 20 such that transfer object 30 slides in direct transfer direction A.
Advantageously, the present invention does not require a separate driving motor or driving roller. Since the physical structures of air nozzles 20 and transfer object 30 do not come into contact with one another but instead maintain a prescribed distance from one another, there is no power loss due to friction thereby enhancing the transfer speed and no contact noise is generated.
Subsequently, as shown in FIGS. 5 , 6 A, and 6 B, when transfer object 30 arrives at the branch point, the plurality of air nozzles 20 ′ stop transfer object 30 by being positioned such that air nozzles 20 ′ make a 90 degree angle relative to the transfer direction of transfer object 30 . Preferably, a separate stopping pin 40 is used as well to stop transfer object 30 at the branch point.
Succeedingly, as shown in FIGS. 7 and 8 , when transfer object 30 is stopped after arriving at the branch point, the plurality of air nozzles 20 ′ are inclined toward branch direction B. The inclination of air nozzles 20 ′ also directs the air injection from the plurality of air nozzles 20 ′ such that transfer object 30 slides in branch direction B. Advantageously, since transfer object 30 can be branched off by simply switching the direction of a certain set of air nozzles 20 ′, a separate feeder for branching off is not needed, and problems with slow transfer speed at branch points can be resolved.
FIG. 9 is a perspective view of a transfer apparatus according to a second embodiment of the present invention, and FIG. 10 is a lateral view of the transfer apparatus shown in FIG. 9 . The same reference numerals in the drawings mentioned above indicate similar parts for performing similar functions.
As shown in FIGS. 9 , 10 , and 13 , a transfer apparatus according to the second embodiment of the present invention includes a support panel 10 operably coupled to a transfer means 50 for transferring a transfer object 30 . Transfer means 50 includes a connection body 51 and a guide line 52 on which connection body 51 is operably coupled and moved by sliding.
A plurality of air nozzles 20 are arranged on support panel 10 , and in a similar manner as described above with respect to the first embodiment, the plurality of air nozzles 20 fix the position of transfer object 30 by injecting or sucking air to form a vacuum status inside each of the plurality of air nozzles 20 while maintaining a specified distance with transfer object 30 . In other words, the physical structures of air nozzles 20 and transfer object 30 do not come into contact with one another and maintain a prescribed distance from one another. In order to do that, air nozzles 20 fix the position of transfer object 30 by injecting air and forming a vacuum status inside each of the plurality of air nozzles 20 to prevent transfer object 30 from straying by the injection of air.
Referring again to FIG. 13 , an air transfer groove 21 is formed inside each air nozzle 20 to form a vacuum status inside air nozzle 20 . Air transfer groove 21 can be formed into various forms such as slanted or spiral shapes.
Accordingly, as connection body 51 is moved along guide line 52 , coupled support panel 10 also moves along guide line 52 , thus moving transfer object 30 which is fixed to air nozzles 20 arranged on support panel 10 .
The operation of the transfer apparatus according to the second embodiment of the present invention having a structure as described above will now be described.
First, transfer object 30 is fixed by a plurality of air nozzles 20 placed on support panel 10 to have a specified distance between the air nozzles and the transfer object.
Next, transfer object 30 is transferred by transfer means 50 connected to the support panel 10 .
Advantageously, it is possible to transfer transfer object 30 without contacting a pattern portion of an LCD formed on transfer object 30 . Furthermore, when the transfer object has to be moved along a different direction, the transfer object may be simply transferred to the other direction by rotating transfer means 50 .
It is also possible to pick up and transfer the transfer object 30 from above as is described in a third embodiment below.
FIG. 11 is a perspective view of a transfer apparatus according to the third embodiment of the present invention, and FIG. 12 is a lateral view of the transfer apparatus shown in FIG. 11 . The same reference numerals as in drawings mentioned above indicate similar parts for performing similar functions.
As shown in FIGS. 11 , 12 , and 13 , a transfer apparatus according to the third embodiment of the present invention includes a support panel 10 and a transfer means 50 for transferring the support panel 10 . Transfer means 50 includes a connection body 51 connected to a top portion of support panel 10 and a guide line 52 on which connection body 51 is operably coupled and moved by sliding.
A plurality of air nozzles 20 are arranged under support panel 10 , and the plurality of air nozzles 20 fix the position of transfer object 30 by injecting or sucking air while maintaining a specified distance with transfer object 30 . In other words, the plurality of air nozzles 20 and transfer object 30 are not contacted but placed to maintain a prescribed distance with each other. In order to do that, air nozzles 20 fix the position of transfer object 30 by injecting air and forming a vacuum status inside each of the plurality of air nozzles 20 to prevent transfer object 30 from straying by the injection of air.
Referring again to FIG. 13 , an air transfer groove 21 is formed inside each air nozzle 20 to form a vacuum status inside air nozzle 20 . Air transfer groove 21 can be formed to have various forms, such as slanted or spiral shapes.
Accordingly, as connection body 51 moves along guide line 52 , coupled support panel 10 also moves along guide line 52 , thus moving transfer object 30 which is fixed to air nozzles 20 arranged on support panel 10 .
The operation of the transfer apparatus according to the third embodiment of the present invention having a structure as described above will now be described.
First, transfer object 30 is fixed by the plurality of air nozzles 20 placed under support panel 10 to have a specified distance between air nozzles 20 and transfer object 30 .
Next, the transfer object 30 is transferred by transfer means 50 connected to the support panel 10 .
Advantageously, it is possible to transfer transfer object 30 without contacting a pattern portion of an LCD formed on transfer object 30 . Furthermore, when the transfer object has to be rotated to be transferred to another direction, the transfer object can be simply transferred to the other direction by rotating transfer means 50 .
Since the present invention transfers the transfer object, in one example a glass substrate, by only using air, the structure of the apparatus becomes simple and investment cost for the initial manufacturing processing device is reduced because a stocker, a cassette, and/or an indexer are not used.
Moreover, yield is enhanced by preventing breaking or cracks due to contact and by preventing chemical or particle contamination by providing transfer of the glass substrate without contacting the glass substrate with the air nozzles.
In addition, since the glass substrate is transferred without friction, the transfer speed is enhanced and the time required for transfer is shortened.
Furthermore, because the glass substrate is transferred only using air, the problem of transfer delay upon changing the transfer direction, for example when the glass substrate is rotated, branched off, joined together, or buffered, is resolved.
Since a gear for connection between power axes, or a chain or a belt which is a medium of power transfer is not needed, noise due to the revolution of the motor and that due to tooth-setting of the gears for connection between power axes are reduced.
It will be apparent that the present invention may be used in conjunction with various processing apparatus in various manufacturing systems such as those described in co-pending U.S. patent application Ser. No. 10/863,064 with the same filing date which is incorporated by reference herein for all purposes.
Although preferred embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that many variations and/or modifications of the basic inventive concepts herein taught which may appear to those skilled in the present art will still fall within the spirit and scope of the present invention, as defined in the appended claims. | A transfer apparatus is provided for the transport of transfer objects such as glass substrates or semiconductor devices in which cleanliness and secure transport are of major concern. A plurality of air nozzles inject air through the plurality of air nozzles to hold a transfer object in place above or below the plurality of air nozzles without the plurality of air nozzles making contact with the transfer object. The plurality of air nozzles are positioned perpendicular to the transfer object to stop and/or engage the transfer object in a rest position. The plurality of air nozzles are inclined to a specified angle to move the transferred object in a desired direction. Advantageously, because the transfer object is moved without physical contact between the structure of the air nozzles and the transfer object, the transfer is secure, clean, and efficient. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of application Ser. No. 10/606,829 filed on Jun. 27, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field of the Invention
[0003] The present invention relates to the chirped pulse amplification of an ultrashort optical pulse, and more specifically, to chirped pulse amplification using commercial telecommunications components, such as a LiNbO 3 modulator for a pulse selector. The present invention further relates to techniques for integration of components together to avoid free space alignment, which results in a more simple assembly process and improved mechanical stability.
[0004] 2. Description of the Related Art
[0005] The following references provide useful background information on the indicated topics, all of which relate to the invention, and are incorporated herein by reference:
A. Galvanauskas and M. E. Fermann, 13- W Average Power Ultrafast Fiber Laser , Conference on Lasers and Electro-Optics 2000, San Francisco, Calif., May 7-12, 2000, post deadline paper CPD3. Y. Jaouen, M. Le Flohic, E. Olmedo and G. Kulscar, 35 kW Subpicosecond Pulse Generation At 1.55 μm Using Er 3+/ Yb 3+ Fiber Amplifier , Conference on Lasers and Electro-Optics 2001, Baltimore, Md., May 6-11, 2001, paper CTuQ3. M. E. Fermann, M. L. Stock, A. Galvanauskas and D. J. Harter, High - Power Ultrafast Fiber Laser , Proceedings of SPIE, 3942, 194 (2000). A. Boskovic, M. J. Guy, S. V. Chemikov, J. R. Taylor, and R. Kashyap, All - Fibre Diode Pumped Femtosecond Chirped Pulse Amplification System , Electronics Letters, 31 (11), 877 (1995).
[0010] With the increasing interest in high-pulse energy femtosecond lasers in applications such as micro-structuring, the emergence of high power high pulse energy fiber lasers has been one of the most exciting developments in optical technology in recent years. Both Galvanauskas et al. and M. E. Fermann et al. have disclosed the achievement of microjoule levels of pulse energy in erbium and ytterbium-based chirped pulse amplification systems. However, at wavelengths of approximately 1550 nanometers, very little research has occurred recently. Researchers in the United Kingdom and France have done some work in this area, but at limited pulse energies. Jaouen et al. have used a peak power of 35 kilowatts and a pulsewidth of 450 femtoseconds, but the pulse energy was only 16 nanojoules. Boskovic et al. only obtained 1.6 nanojoules after amplification without down-counting the repetition rate from the source laser.
[0011] In most chirped pulse amplification systems, an acousto-optic (AO) modulator is used to select the pulses to be amplified. However, at wavelengths around 1550 nanometers, such an acousto-optic modulator is not readily available due to material limitations, especially when the original pulse repetition rate is higher than 20 megahertz. For example, if a mode-locked laser source with a pulse repetition rate of 50 megahertz is used, in order to select a pulse from the initial pulse train, less than 10 nanoseconds in rise time and fall time is normally required. However, at such a speed, acousto-optic modulators working at 1550 nanometers are either not readily available or very expensive. In addition, such modulators have high insertion losses. For example, Brimrose manufactures an AO modulator with acceptable performance at 1550 nanometers, but each modulator costs several thousand dollars. Such high costs can limit mass production of amplification systems using such AO modulators.
[0012] On the other hand, at 1550 nanometers, high speed electro-optic (EO) modulators (such as LiNbO 3 ) working at 2.5 GHz/s and above (2.5 GHz/s, 10 GHz/s, even 40 GHz/s) are readily available and relatively cheap, due to the large inventory available in the telecommunications industry. A fiber pigtailed 2.5 GHz/s LiNbO 3 modulator can be purchased for less than a thousand dollars. No chirped pulse amplification system, however, has ever used such an electro-optic modulator system.
[0013] A LiNbO 3 electro-optic modulator is a type of Mach-Zehnder modulator. A LiNbO 3 modulator comprises an integrated optical waveguide on a material that can exhibit electro-optic effects. Electro-optic materials have an index of refraction that can be changed with the application of voltage. Mach-Zehnder modulators operate using interferometry techniques. The optical signal is branched into two separate paths and is then recombined at the output. The two paths of the interferometer are nearly, but not exactly, the same length. When the two optical signals from the two paths are combined at the output, the two signals will have a slightly different phase. If these two signals are exactly in phase, then the light will combine in the output waveguide with low loss. However, if the two signals are 180° out of phase, the light will not propagate in the output waveguide and as a result, it will radiate into the surrounding substrate. The electro-optic effect makes the velocity of propagation in each path dependent on the voltage applied to the electrode. As a result, depending on the modulation voltage, the light will propagate with high or low loss at the output waveguide.
[0014] Commercial telecommunications modulators all have fiber pigtails aligned to the input and output waveguides. The input fiber pigtail has to be a polarization-maintaining fiber, since Mach-Zehnder modulators must have a specific input polarization state to function properly. But the output fiber pigtail can be either polarization-maintaining or non-polarization-maintaining fiber, depending on the application.
[0015] In a typical chirped pulse amplification system, a stretcher and one or two pre-amplifiers are needed, as well as the pulse selector before the power amplifier. The stretcher can be a bulk grating or fiber grating, or a fiber stretcher, as discussed in U.S. Pat. No. 5,847,863 issued to Galvanauskas et al., and hereby incorporated by reference in its entirety. However, even if a fiber-based device was used as stretcher, it was heretofore assembled using free space alignment, wherein a coupling element (e.g., a lens) coupled the input pulse into the fiber. Although technically sufficient, the coupling element is not suited to mass production, due to the labor-intensive assembly involved. In addition, the long-term operational stability of the system is usually an issue as well. For example, the coupling has to be frequently adjusted to ensure high throughput.
[0016] An erbium-doped fiber amplifier is a common active device, which uses a certain length of erbium-doped fiber and a pump diode (operating at either 980 nanometers or 1480 nanometers). Due to the non-polarization-maintaining nature of the erbium-doped fiber, a double pass configuration has to be used to maintain the polarization. Due to the polarization sensitive nature of the LiNbO 3 modulator, it can not be used in the same double pass loop with other non-polarization-maintaining fiber components.
[0017] Normally, a LiNbO 3 modulator has a low extinction ratio (˜23 decibels), which results in a low signal/noise contrast ratio, typically around 20-23 decibels. This low signal/noise contrast ratio is inadequate for a chirped pulse amplification system, and has to be increased to at least 30 decibels, or higher. In order to achieve this, either the polarization extinction ratio of the modulator must be improved, or other methods have to be exploited to increase the signal/noise contrast ratio.
SUMMARY OF THE INVENTION
[0018] The invention has been made in view of the above circumstances and to overcome the above problems and limitations of the prior art, and provides an erbium fiber (or erbium-ytterbium) based chirped pulse amplification system operating at a wavelength of approximately 1550 nanometers. The use of fiber amplifiers operating in the telecommunications window enables the implementation of telecommunications components and telecommunications compatible assembly procedures with superior mechanical stability.
[0019] Additional aspects and advantages of the invention will be set forth in part in the description that follows and in part will be obvious from the description, or may be learned by practice of the invention. The aspects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
[0020] The above and other aspects and advantages of the invention will become apparent from the following detailed description and with reference to the accompanying drawing figures.
[0021] All technical articles, patents and patent applications referenced herein are here by incorporated by reference as if bodily contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings, which are incorporated in and constitute a part of this specification illustrate embodiments of the invention and, together with the description, serve to explain the aspects, advantages and principles of the invention. In the drawings,
[0023] FIG. 1 illustrates a LiNbO 3 modulator being used as a pulse selector on the output from a mode-locked laser;
[0024] FIGS. 2 a and 2 b illustrate beam propagation and polarization in the polarization-maintaining beam router, according to the present invention;
[0025] FIGS. 3 a and 3 b illustrate beam propagation and polarization in the polarization-maintaining circulator, according to the present invention;
[0026] FIGS. 4 a and 4 b illustrate a double pass stretcher system using the polarization maintaining beam router or the polarization-maintaining circulator and a non-polarization-maintaining dispersion compensating fiber or fiber grating, according to the present invention;
[0027] FIGS. 5 a and 5 b illustrate a double pass pulse stretcher cascaded with an erbium doped fiber amplifier, according to the present invention;
[0028] FIG. 6 illustrates a first chirped pulse amplification system using a polarization-maintaining beam router/circulator and a modulator, according to the present invention;
[0029] FIG. 7 illustrates a second chirped pulse amplification system using a polarization-maintaining beam router/circulator and a polarization-insensitive modulator, according to the present invention;
[0030] FIG. 8 illustrates a third chirped pulse amplification system using a polarization-maintaining beam router/circulator and two polarization-insensitive modulators, with one operating as a second pulse selector, according to the present invention;
[0031] FIG. 9 illustrates cascaded modulators for improving contrast ratio; and
[0032] FIG. 10 shows the spectrum and pulse profile after the pulse compressor in a system described in FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] A detailed description of the preferred embodiments of the invention will now be given referring to the accompanying drawings.
[0034] For chirped pulse amplification systems operating at wavelengths of approximately 1550 nanometers, acousto-optic modulators with fast rise times have limited availability, due to lack of appropriate materials. However, the telecommunications electro-optic modulators and electro-absorption modulators provide an alternative solution. Such modulators, however, have not been used in a chirped pulse amplification system for the purpose of pulse selection. Referring to FIG. 1 , a chirped pulse amplification system is illustrated. A mode-locked laser 10 outputs a pulse stream 11 , which is input into a modulator 12 . The modulator 12 then modulates the incoming pulse stream 11 , and outputs the selected pulses 13 . The modulator 12 can be a LiNbO 3 electro-optic modulator or an electro-absorption modulator.
[0035] In the present invention, a LiNbO 3 modulator is used as a pulse selector. Using a conventional down-counter electronics circuit, a modulator voltage was applied to the LiNbO 3 modulator, thereby enabling pulse selection from a 50 megahertz mode-locked laser source to as low as around 100 kilohertz. Both input and output pigtail fibers must be polarization-maintaining fiber in order to maintain the polarization states during the pulse selection, since the LiNbO 3 modulator is polarization sensitive. A clean pulse train at the corresponding repetition rate can be generated in this manner.
[0036] Electro-optic modulators and electro-absorption modulators accumulate nonlinear effects at peak intensity (i.e., approximately 200 Watts), so the pulse is stretched before being injected into the modulator. For a polarization-sensitive modulator like a LiNbO 3 modulator, polarization-maintaining fiber must be used at the input, but the output fiber can be both polarization-maintaining fiber and non-polarization-maintaining fiber. In the preferred embodiment, the polarization in the whole system is maintained, so the output fiber of the modulator is also polarization-maintaining fiber.
[0037] Several types of stretchers can be used in a chirped pulse amplification system. Initially, a first pair of bulk gratings are used to stretch the input pulse and then compressed back after amplification by using a second pair of bulk gratings. The second pair of bulk gratings has parameters similar to the first pair of bulk gratings. Alternatively, linear or non-linear fiber gratings or even a length of fiber can serve as pulse stretcher, as long as the fiber or the fiber grating has the right dispersion value.
[0038] Preferably, commercially available dispersion compensating fiber or dispersion shifted fiber is used as stretcher fiber, and fairly good performance is obtained. However, since a long length of fiber has to be used, accumulated third order dispersion due to the stretcher fiber is not negligible. Although second order dispersion from the stretcher fiber can be easily compensated by the compressor grating system, the accumulated third-order dispersion was added together by the compressor grating and the final pulse width is always wider than the initial pulse width from the mode-locked laser. In order to compensate both the second-order and third order dispersion in the system, a nonlinearly chirped fiber grating with matched bandwidth to the mode-locked laser source is more desirable, or a specially designed fiber with proper second- and third-order dispersion which match those in the compressor gratings can be used.
[0039] In case of a non-polarization-maintaining fiber stretcher, a double pass configuration has to be used to maintain the polarization. Typically, a combination of a polarization beam splitter cube and a Faraday rotator mirror is used. Conventionally, the source beam from a mode-locked laser or from a pulse selector passes through the polarization beam splitter, and then the output from the polarization beam splitter was coupled into the stretcher via free space. After the double pass and pass through the polarization beam splitter, the stretched pulse was either sent to the pulse selector or to a pre-amplifier.
[0040] In order to utilize telecommunications assembly procedures (i.e., integration, fiber splicing) and due to the fiber-based nature of the present invention, a polarization-maintaining beam router and a polarization-maintaining circulator are used. Basically, the polarization-maintaining beam router and polarization-maintaining circulator operate in the same manner as a free space polarization beam splitter, but with polarization-maintaining fiber. With advances in telecommunications technologies, packaging such a device is a relatively easy task and it can be hermetically sealed if necessary.
[0041] By combining a polarization-maintaining beam router or a polarization-maintaining circulator with a Faraday rotator mirror, polarization can be maintained even with non-polarization-maintaining fibers. In addition, conventional telecommunications assembly procedures can be used. As shown in FIGS. 3 a , 3 b , 4 a and 4 b , by properly matching the fiber slow axis to the desired beam polarization, system polarization can be maintained with fiber splicing.
[0042] For example, a s-polarized beam (relative to the polarization beam splitter) entering a polarization beam splitter at a first port will be directed to a second port. Due to the Faraday rotator mirror, the polarization of the reflected beam will rotate by 90°, and can then traverse through the beam splitter and be directed towards a third port. If the pigtailed polarization-maintaining fiber at the third port has the slow axis (or the fast axis depending on the polarization in the next fiber component) aligned to the p-polarized beam, then the polarization of the whole system is maintained after the double pass configuration. A polarization-maintaining circulator can be constructed from the same design, in which a Faraday rotator and a Faraday rotator mirror are added into the packaging and the polarization-maintaining fiber at the third port is oriented at 45° relative to the polarization beam splitter. Using currently available telecommunications fiber-pigtailed components, the front end of a chirped pulse amplification system can be built easily and rigidly. Advantageously, all the components can be connected together by simply splicing them together.
[0043] Referring to FIG. 2 a , a polarization-maintaining beam router is illustrated. The source pulse enters at the first port 21 of the polarization beam splitter 20 . The polarization-maintaining fiber 22 is aligned such that the incoming source pulse will propagate in the polarization-maintaining fiber 22 in an s-polarization state relative to the polarization beam splitter 20 . For the polarization-maintaining fiber 22 , alignment with either propagation axis is permissible. The incoming source pulse is collimated and directed to the second port 23 . The second port 23 is coupled to a second polarization-maintaining fiber 24 . For the second polarization-maintaining fiber 24 , alignment with either propagation axis is permissible. For example, in a fiber-based device, a non-polarization-maintaining dispersion compensating fiber 26 can be directly spliced to the polarization-maintaining fiber 24 attached to the second port 23 . A pigtailed Faraday rotator 25 and a mirror 27 are spliced to the dispersion compensating fiber 26 to create the double pass loop. The optical device 30 coupled between the Faraday rotator 25 and the mirror 27 is transmissive. The Faraday rotator 25 and the mirror 27 cause the collimated input pulse to be reflected back into polarization beam splitter 20 , but with the pulse polarization rotated by 90°. Due to the polarization rotation, the input pulse can now transit through the polarization beam splitter 20 and is coupled to the third port 28 . Assuming that the input pulse propagates along the slow axis in all the polarization-maintaining fibers, then the polarization-maintaining fiber 29 coupled to the third port 28 has to be aligned such way that the slow axis matches with the p-polarization relative to the polarization beam splitter 20 .
[0044] Referring to FIG. 2 b , an alternative polarization-maintaining beam router is illustrated. The source pulse enters at the first port 21 of the polarization beam splitter 20 . The polarization-maintaining fiber 22 is aligned such that the incoming source pulse will propagate in the polarization-maintaining fiber 22 in an s-polarization relative to the polarization beam splitter 20 . For the polarization-maintaining fiber 22 , alignment with either propagation axis is permissible. The incoming source pulse is collimated and directed to the second port 23 . The second port 23 is coupled to a second polarization-maintaining fiber 24 . For the second polarization-maintaining fiber 24 , alignment with either propagation axis is permissible. In a fiber-based device, a non-polarization-maintaining dispersion compensating fiber 26 can be directly spliced to the polarization-maintaining fiber 24 attached to the second port 23 . Different from FIG. 2 a , a faraday rotator mirror was used at the end of the loop to create the double pass. The optical device 30 , such as a fiber grating (which is a mirror), coupled after the Faraday rotator 25 not is transmissive. The Faraday rotator 25 and the optical device 30 cause the collimated input pulse to be reflected back into polarization beam splitter 20 , but with the pulse polarization rotated by 90°. Due to the polarization rotation, the input pulse can now transit through the polarization beam splitter 20 and is coupled to the third port 28 . Assuming that the input pulse propagates along the slow axis in all the polarization-maintaining fibers, then the polarization-maintaining fiber 29 coupled to the third port 28 has to be aligned such that the slow axis matches with the p-polarization relative to the polarization beam splitter 20 .
[0045] Referring to FIG. 3 a , a polarization-maintaining beam router converted into a polarization-maintaining circulator is illustrated. Using the polarization-maintaining beam router depicted in FIG. 2 a , a Faraday rotator mirror 41 and a Faraday rotator 42 are added in the polarization circulator 40 . In this embodiment, instead of an optical device 30 having non-transmissive properties, an optical device 30 with transmissive properties is used. Therefore, a Faraday rotator mirror 43 is required. The polarization-maintaining fiber 29 coupled to the third port 28 has to be aligned 45° relative to the polarization beam splitter 40 . Assuming a light pulse with s-polarization relative to the polarization beam splitter 40 is input into the first port 21 , it is directed to the second port 23 as discussed above. After being reflected back from the second port 23 by the Faraday rotator 25 and the mirror 27 , it is coupled into the polarization-maintaining fiber 29 at the third port 28 . As discussed above, the slow axis of the polarization-maintaining fiber 29 is coupled to the third port 28 . If a light pulse propagating on the slow axis of the polarization-maintaining fiber 29 coupled to the third port 28 is injected back into the polarization circulator 40 , the Faraday rotator 42 will rotate the light pulse by 45°. The light pulse will be directed to the Faraday rotator mirror 41 located opposite to the first port 21 . After reflecting back from the Faraday rotator mirror 41 , it will be directed to the first port 21 .
[0046] Referring to FIG. 3 b , a second polarization-maintaining circulator is illustrated. Using the polarization-maintaining beam router depicted in FIG. 2 b , a Faraday rotator mirror 41 and a Faraday rotator 42 are added in the polarization circulator 40 . The second polarization-maintaining circulator operates in the same manner as the first polarization-maintaining circulator described above. By using either of the polarization-maintaining beam routers illustrated in FIGS. 2 a and 2 b , or the polarization-maintaining circulators illustrated in FIGS. 3 a and 3 b , a double pass configuration system can be built by simply splicing non-polarization-maintaining fibers together.
[0047] Referring to FIG. 4 a , a double pass polarization-maintaining stretcher is depicted. A single mode non-polarization-maintaining dispersion compensating fiber 51 is coupled between a polarization-maintaining beam router 50 and a Faraday rotator mirror 52 . A polarization-maintaining circulator can be used instead of the polarization-maintaining beam router. Referring to FIG. 4 b , a second double pass polarization-maintaining stretcher is depicted. As with the previous stretcher system, a polarization-maintaining beam router 50 is used, or in the alternative, a polarization-maintaining circulator can be used. Instead of a Faraday rotator mirror, the second double pass polarization-maintaining stretcher uses a Faraday rotator 53 and a non-polarization-maintaining fiber grating 54 . The fiber grating 54 can be either linearly or nonlinearly chirped.
[0048] Referring to FIG. 5 a , a double pass stretcher is cascaded with an erbium-doped fiber amplifier. A polarization-maintaining beam router 60 is coupled to a single mode non-polarization-maintaining dispersion compensating fiber 61 , which is then coupled to a 1480/1550 nanometer wavelength division multiplexer 62 . A polarization-maintaining beam circulator can be substituted for the polarization-maintaining beam router 60 . A 1480 nanometer pump diode 65 is coupled to the 1480/1550 nanometer wavelength division multiplexer 62 . An erbium-doped fiber amplifier 63 is coupled between a Faraday rotator mirror 64 and the 1480/1550 nanometer wavelength division multiplexer 62 . Referring to FIG. 5 b , a second double pass stretcher is cascaded with a ytterbium/erbium doped fiber amplifier. A polarization-maintaining beam router 60 is coupled to a single mode non-polarization-maintaining dispersion compensating fiber 61 , which is then coupled to a 980/1550 nanometer wavelength division multiplexer 66 . A polarization-maintaining beam circulator can be substituted for the polarization-maintaining beam router 60 . A 980 nanometer pump diode 68 is coupled to the 980/1550 nanometer wavelength division multiplexer 66 . A ytterbium/erbium fiber amplifier 67 is coupled between a Faraday rotator mirror 64 and the 980/1550 nanometer wavelength division multiplexer 66 .
[0049] Referring to FIG. 6 , a chirped pulse amplification system according to the present invention is depicted, and the amplification system uses a fiber-based polarization-maintaining double pass configuration with non-polarization-maintaining components. A polarization-maintaining beam router 70 is coupled to a single mode non-polarization-maintaining dispersion compensating fiber 71 , which is then coupled to a wavelength division multiplexer 72 . A pump diode 73 is coupled to the wavelength division multiplexer 72 . An amplifier fiber 74 is coupled between a Faraday rotator mirror 75 and the wavelength division multiplexer 72 . A mode-locked laser 76 supplies input pulses to the polarization-maintaining beam router 70 . The output pulses from the polarization-maintaining beam router 70 are selected using the earlier described electro-optic modulator 77 as a pulse selector. An amplifier 78 amplifies the output pulses, and then a compressor 79 compresses the output pulses.
[0050] Due to the polarization sensitive nature of the LiNbO 3 modulator, it can not be used in the same double pass loop with other non-polarization-maintaining fiber components. However, the electro-absorption modulator has low power consumption, low drive voltage, small size, large electro-optic bandwidth, and most importantly, is polarization-insensitive. Therefore, an electro-absorption modulator can de disposed inside the double pass loop with other non-polarization-maintaining components, which can result in a more compact configuration. As shown in FIGS. 7 and 8 , the modulator is either in the same loop of the stretcher and erbium doped fiber amplifier, or in the final power amplifier and used as the second pulse selector.
[0051] Referring to FIG. 7 , a modulator can be added into the double pass loop in order to lower the cost and design a more compact system. Although this is not feasible for the LiNbO 3 modulator due to polarization limitations, another type of modulator can fulfill such function. An electro-absorption modulator is not polarization sensitive. Therefore, the electro-absorption modulator can be cascaded with a pulse stretcher and a pre-amplifier, such as an erbium doped fiber amplifier.
[0052] As illustrated in FIG. 7 , a second chirped pulse amplification system according to the present invention is depicted. A polarization-maintaining beam router 80 is coupled to a single mode non-polarization-maintaining dispersion compensating fiber 82 operating as a pulse stretcher. A mode-locked laser 81 supplies input pulses to the polarization-maintaining beam router 80 . A typical output pulse from the mode-locked laser 81 is a 50 megahertz, 300 femtosecond pulse, having a power of 0.1 nanojoule at 5 milliwatts. A pre-amplifier fiber 83 is coupled between the non-polarization-maintaining dispersion compensating fiber 82 acting as a pulse stretcher and an electro-absorption modulator 84 . In general, the modulator can be spliced into any position in the double pass loop as long as the selected pulse can pass through the opened gate. Typically, the characteristics of the pulse at the pulse stretcher are 200-300 picoseconds, at 50 megahertz, 3 milliwatts and 0.06 nanojoules. A Faraday rotator mirror 85 is coupled to the electro-absorption modulator 84 . The output of the polarization-maintaining beam router 80 is coupled to a beam splitter 86 . In the present invention, output pulses from the polarization-maintaining beam router 80 are approximately 200-300 picoseconds, at 200 kilohertz and 10 nanojoules. A ytterbium/erbium erbium doped fiber amplifier 87 is coupled between the beam splitter 86 and a Faraday rotator mirror 88 . Preferably, the ytterbium/erbium erbium doped fiber amplifier 87 is a multimode amplifier that is pumped to 4 Watts. The pulses output from the beam splitter 86 are generally 200-300 picoseconds in length at a 200 kilohertz repetition rate, and are 400 milliwatts and greater than 2 microjoule in strength.
[0053] Referring to FIG. 8 , a third chirped pulse amplification system according to the present invention is depicted. A polarization-maintaining beam router 90 is coupled to a fiber grating 92 that is either linearly or nonlinearly chirped, and acting as a pulse stretcher. Typically, the characteristics of the pulse at the pulse stretcher are 200-300 picoseconds, at 50 megahertz, 3 milliwatts and 0.06 nanojoules. A mode-locked laser 91 supplies input pulses to the polarization-maintaining beam router 90 . A typical output pulse from the mode-locked laser 81 is a 50 megahertz, 300 femtosecond pulse, having a power of 0.1 nanojoule at 5 milliwatts. The output of the polarization-maintaining beam router 90 is coupled to a first modulator 93 (electro-optic or electro-absorption) in order to down-count the repetition rate from the mode-locked laser 91 . The output of the first modulator 93 is coupled to a beam splitter 94 , and a ytterbium/erbium or erbium doped fiber amplifier 95 is coupled between the beam splitter 94 and a second modulator 96 (electro-absorption). In the present invention, output pulses from the first modulator 93 are approximately 200-300 picoseconds in length, at a 10 megahertz repetition rate, at 0.3 milliwatts and 0.03 nanojoules. The second modulator decreases the pulse repetition rate further and the selected pulses can pass through the second modulator 96 and are amplified in the ytterbium/erbium erbium doped fiber amplifier 95 . Preferably, the ytterbium/erbium or erbium doped fiber amplifier 87 is a multimode amplifier that is pumped to 4 Watts. A Faraday rotator mirror 97 reflects and rotates the pulses that output from the second modulator 96 . The pulses output from the beam splitter 94 are generally 200-300 picoseconds in length at a 400 kilohertz repetition rate, and are 400 milliwatts and greater than 1 microjoule in strength. Prior to being output into the system, the amplified pulses are compressed back to femtosecond or picosecond range.
[0054] As shown in FIG. 8 , the selected pulses can be amplified using a double pass side-pumping scheme. In addition, an end-pumping configuration can also be used to amplify the selected pulses, and usually it gives a higher output power and higher pulse energy due to the availability of the high-power multimode pump diodes. Due to the nonlinearity, the amplifier fiber used in the final amplifier has to be multimode fiber. The larger the core size, the less severe the nonlinear effect, but the more difficult to control the single mode operation. In U.S. Pat. No. 5,818,630 issued to Fermann et al., a mode filter and/or mode-converter was used to control single mode operation in such a multimode system. In the present invention, however, by carefully aligning the amplifier fiber relative to the seed and the pump, single mode operation can be achieved in double clad multimode fiber without any mode filter or mode converter, with fiber core size up to 20 micrometers. When fiber core size is larger than 25 micrometers, single mode operation can still be achieved, but it is difficult to maintain the single mode, especially when touching or moving the fiber.
[0055] Usually, poor contrast ratio is expected from an electro-optic modulator or an electro-absorption modulator (<23 decibels). But for a chirped pulse amplification system, a contrast ratio of 30 decibels or above is normally required, especially in the case of 100:1 (or higher) pulse selection. In order to achieve the required contrast ratio, a second modulator is cascaded and synchronized with a first modulator. With one electro-absorption modulator in a double pass configuration, or, two electro-optic modulators or electro-absorption modulators in cascaded sequence and with synchronizing electronics, the contrast ratio can be doubled. In addition, adding a second erbium doped fiber amplifier between the pulse selector and the power amplifier easily boosts the contrast ratio to at least 30 decibels.
[0056] Referring to FIG. 9 , a pulse stream from a mode-locked laser 100 is input into a first modulator 101 . The first modulator 101 can be an electro-optic modulator or an electro-absorption modulator. The first modulator 101 is coupled to a second modulator 102 , which also can be an electro-optic modulator or an electro-absorption modulator. A synchronizer circuit 103 synchronizes the first modulator 101 with the second modulator 102 . In operation, the selected pulse from the first modulator 101 can pass through the second modulator 102 with negligible loss. A rejected pulse from the first modulator 101 will incur a high loss at the second modulator 102 , so the contrast ratio can be doubled after the second modulator 102 . Another solution to this is to add a second erbium doped fiber amplifier (or a ytterbium/erbium or erbium doped fiber amplifier) between the modulator and the final amplifier. A 30 decibel contrast ratio is readily achievable from this approach.
[0057] By using commercially available modulators (LiNbO 3 modulator), the present invention can down count a 50 megahertz, 300 femtosecond pulse from an IMRA Femtolite laser to as low as 100 kilohertz, and obtain over 1.2 Watts output from a double clad ytterbium/erbium erbium doped fiber amplifier at 19 Watt pump. At 200 kilohertz repetition rate, the present invention can obtain 2 microjoules and 820 femtoseconds after compression. The spectrum and pulse profiles are shown in FIG. 10 .
[0058] The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. Similar can be obtained at other wavelength such as 1.06 μm for a Yb-doped fiber system. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
[0059] Thus, while only certain embodiments of the invention have been specifically described herein, it will be apparent that numerous modifications may be made thereto without departing from the spirit and scope of the invention. The invention thus includes a number of aspects which may be generally characterized as follows:
[0060] In one broad aspect, the invention may be characterized as a chirped pulse amplifier for a fiber optic system, including a mode-locked laser and a pulse selector coupled to an output of the mode-locked laser, wherein the pulse selector modulates an output stream of pulses based upon an applied modulation voltage. Herein, the pulse selector may be an electro-optic modulator, which may be a LiNbO 3 modulator, or an electro-absorption modulator.
[0061] According to another aspect of the invention, the invention can be characterized as a chirped pulse amplifier for a fiber optic system, including a mode-locked laser, a polarization-maintaining device coupled to an output of the mode-locked laser, a pulse stretcher coupled to a first output of the polarization-maintaining device, an amplifier coupled to the pulse stretcher, and a first pulse selector coupled to a second output of the polarization-maintaining device. Herein, the pulse stretcher may include one of: (1) a non-polarization-maintaining dispersion compensating fiber and a Faraday rotator mirror; (2) a non-polarization-maintaining dispersion shifted fiber and a Faraday rotator mirror; (3) a linearly chirped fiber grating and a Faraday rotator; or (4) a non-linearly chirped fiber grating and a Faraday rotator, or like devices.
[0062] Further herein, the amplifier may include an erbium doped fiber amplifier or a erbium/ytterbium or a ytterbium doped fiber amplifier; a wavelength division multiplexer; and a diode pump.
[0063] Further herein, the first pulse selector may again be an electro-optic modulator or an electro-absorption modulator.
[0064] Further herein, the polarization-maintaining device comprises a polarization-maintaining beam router, wherein a fiber axis orientation of the input and output fibers matches the orientation of the polarization beam splitter. In addition, a Faraday rotator may be disposed at a first port of the polarization-maintaining beam router and a Faraday rotator mirror at that port of the polarization-maintaining beam router in case the optical device is transmissive.
[0065] This aspect of the invention may further include a second pulse selector coupled to an output of the first pulse selector; and a synchronization controller that synchronizes the first pulse selector with the second pulse selector. The second pulse selector is again an electro-optic modulator or an electro-absorption modulator.
[0066] According to a further aspect, the invention may be characterized as a chirped pulse amplifier for a fiber optic system operating at approximately 1550 nanometers or other wavelength, the amplifier including a mode-locked laser; a polarization-maintaining device coupled to an output of the mode-locked laser; a pulse stretcher coupled to a first output of the polarization-maintaining device; a first amplifier coupled to the pulse stretcher; a pulse selector coupled to the first amplifier; and a second amplifier coupled through a beam splitter to a second output of the polarization-maintaining device. Herein, the pulse stretcher may be embodied variously, including (1) a polarization-maintaining dispersion compensating fiber and a Faraday rotator mirror, wherein the pulse selector is coupled between the first amplifier and the Faraday rotator mirror; (2) a polarization-maintaining dispersion shifted fiber and a Faraday rotator mirror, wherein the pulse selector is coupled between the first amplifier and the Faraday rotator mirror; (3) a linearly chirped polarization-maintaining fiber grating and
[0067] a Faraday rotator, wherein the pulse selector is coupled between the first amplifier and the Faraday rotator; or (4) a non-linearly chirped polarization-maintaining fiber grating and a Faraday rotator, wherein the pulse selector is coupled between the first amplifier and the Faraday rotator.
[0068] Further herein, the first amplifier may be an erbium doped fiber amplifier or a erbium/ytterbium doped fiber amplifier or a ytterbium doped fiber amplifier;
[0000] a wavelength division multiplexer; and a diode pump. The pulse selector again may be an electro-optic modulator or an electro-absorption modulator.
[0069] Further herein, the polarization-maintaining device can be a polarization-maintaining beam router, wherein a fiber axis orientation of the input and output fibers matches the orientation of the polarization beam splitter, and may include a Faraday rotator disposed at a first port of the polarization-maintaining beam router and a Faraday rotator mirror at that port of the polarization-maintaining beam router in case the optical device is transmissive.
[0070] Further herein, the second amplifier can be a double clad multimode amplifier fiber operating as a single mode amplifier. In such a case, the multimode amplifier fiber core may be less than or equal to 20 micrometers in diameter.
[0071] According to a yet further aspect of the invention, the invention can be characterized as a chirped pulse amplifier for a fiber optic system, including a mode-locked laser, a polarization-maintaining device coupled to an output of the mode-locked laser, a pulse stretcher coupled to a first output of the polarization-maintaining device, a first pulse selector coupled to a second output of the polarization-maintaining device, a second amplifier coupled through a beam router to an output of the first pulse selector; and a second pulse selector coupled to the second amplifier.
[0072] Herein, the pulse stretcher can be a linearly chirped fiber grating and a Faraday rotator; or a non-linearly chirped fiber grating and a Faraday rotator, among various examples. The first pulse selector can again be an electro-optic modulator or an electro-absorption modulator. Further herein, the polarization-maintaining device can again include a polarization-maintaining beam router, wherein a fiber axis orientation of the input and output fibers matches the orientation of the polarization beam splitter, together with a Faraday rotator disposed at a first port of the polarization-maintaining beam router; and a Faraday rotator mirror at that port of the polarization-maintaining beam router in case the optical device is transmissive.
[0073] Further according to this aspect, the second amplifier can be double clad multimode amplifier fiber operating as a single mode amplifier, in which case the double clad multimode amplifier fiber core is less than or equal to 20 micrometers in diameter.
[0074] Any acronyms that are used merely to enhance the readability of the specification and claims. It should be noted that these acronyms are not intended to lessen the generality of the terms used and they should not be construed to restrict the scope of the claims to the embodiments described therein. | An erbium fiber (or erbium-ytterbium) based chirped pulse amplification system is illustrated. The use of fiber amplifiers operating in the telecommunications window enables the implementation of telecommunications components and telecommunications compatible assembly procedures with superior mechanical stability. | 7 |
FIELD AND BACKGROUND OF THE INVENTION
[0001] This present invention relates to a method and an apparatus for the cyclical volumetric portioning of liquids and pasted products based on the predetermined target volume, i.e., for cyclically producing, during each cycle, portions of the dosed product best matching the predetermined target volume. The invention is particularly useful for portioning high viscosity, corrosive and aggressive liquid products used in chemical and food industries, and is therefore described below with respect to such applications.
[0002] Packing and/or filling machines must operate at a required speed, and must also include, in each package or a container, at least a minimum volume or weight of a dosed product specified on a package or container, hereinafter referred to as the predetermined target volume. It is virtually impossible, from a practical standpoint, to produce portions with volumes exactly according to a specified targeted volume, and therefore machines generally produce portions with excess volumes over the target volume. Since such excess volume is a “give-away” loss to a producer, it is very important to minimize this excess volume as much as possible.
[0003] A few types of dose-volume or volume filling machines are now in common use:
[0004] Overflow Liquid Filling Machines.
[0005] This type of filler is perhaps the most widely used machine in small bottle filling operations because it handles a wide range of thin, free flowing liquids as well as liquids with medium viscosity. This machine is also commonly referred to as a “fill to level” filling machine or cosmetic height filler. This means that machine fills to a target fill height in the container rather than volumetrically. But it can also be shown that as long as the container specification do not vary greatly, the volumetric accuracy of this machine is excellent.
[0006] Because this filler operates in a closed loop basis, it is also ideal for handling foamy products. The Examples of products that work well in this filler are bottled water, liquid soap, motor oil, cleansers and even some dairy products. It can be constructed in both chemical duty versions as well as sanitary versions capable of filling pasteurized products at high temperatures. This machine is relatively low cost and easy to use.
[0007] Servo Pump Liquid Filling Machines.
[0008] This type of machine is a very versatile filling machine capable of filling nearly any type of product that can be pumped. Each nozzle has a dedicated servo controlled pump that can deliver thin liquids, medium and thick viscosity liquids, and liquids with large particulates. Because it is so versatile, it is often purchased by contract packagers who never know what their next filling challenge is going to be. Examples of the range of products that can be run on this machine include soaps, pharmaceutical products, oils and greases, cosmetics, salsa and sauces, etc. This type of filler is an outstanding choice for nearly any type of filling operation.
[0009] Peristaltic Liquid Filling Machines
[0010] This filler is the machine of choice for high value, small volume fills at very high accuracy. It is primarily suitable for aqueous and other light viscosity products. Examples of products filled on this machine are sterile and pharmaceutical preparations, fragrances, essential oils, reagents, inks, dyes, and specialty chemicals. The unique advantage of this machine is that the only fluid path is surgical tubing. The fluid path is disposable, easy to cleanup and eliminates cross contamination problems. Accuracies of 0.5% are achievable for fill volumes less than 1 ml.
[0011] The peristaltic pumps on this filling machine make intermittent contact on only the outside of the surgical (product) tubing so that the product only touches the inside of the tubing. Like the servo pump filling machine above, this system operates with servo drives. Each servo drive is dedicated to one or two peristaltic pump heads. The filler's master computer independently tracks the # of rotations of the peristaltic pump head so that it knows precisely how much product has been delivered. When the target fill volume is reached, the pump stops and the remaining product fluid does not drip out due to pipette action of the surgical tubing.
[0012] Time Gravity Liquid Filling Machines.
[0013] This is the most economical type of filling machine for a limited range of applications. This filler is best suited for liquids with very thin viscosities that do not change with ambient temperature or with batch variation. This machine is also suited for applications where recirculation of the liquid in the fluid path is not desirable. This is especially true for corrosive chemical filling like acids and bleach. Other examples of products this machine is well suited to include water, solvents, alcohol, specialty chemicals, paint and inks. Although this type of filler is used predominantly on products that do not foam, foam may be limited and controlled by subsurface/bottom-up fill capability.
[0014] The machine works by a simple principle; the amount of liquid flowing through a fluid path will always be the same for a fixed amount of time. It functions as follows: the product bulk supply is pumped into a holding tank above a set of pneumatically operated valves. Each valve is independently timed by the filler's master computer so that precise amounts of liquid will flow by gravity into the container. Independent timing of each filling valve/nozzle corrects for minor variations in flow rates so that each container is filled accurately.
[0015] Piston Liquid Filling Machines
[0016] The piston filler is one of the oldest and most reliable types of fillers used in the packaging industry. This filling machine is best suited for viscous products that are paste, semi paste, or chunky with large particulates. Piston fillers are primarily built to meet food grade standards and commonly fill heavy sauces, salsas, salad dressings, cosmetic creams, heavy shampoo, gels, and conditioners. They are also used for viscous chemical preparations like paste cleaners and waxes, adhesives and epoxy's, heavy lubricant oils and greases.
[0017] The machine works by a simple principle. The piston is drawn back in its cylinder so that the product is sucked into the cylinder. A rotary valve then changes position so that the product is then pushed out of the nozzle instead of back into the hopper. The volume of the product that is sucked into the cylinder is the precise volume that will be dispensed into the container.
[0018] The advantage of this type of filling machine is that involves conventional mechanical technology that is easy to understand for most users. It is also the most cost effective, accurate and fastest way to fill fairly thick products. Although more costly than overflow and time gravity systems discussed above, it costs less than the servo pump filler is still the most cost effective filling machine for thick products.
[0019] Net Weight Liquid Filling Machines
[0020] This type of filler is best suited for liquids filled in bulk quantities e.g. 5 gallon pails, etc. or smaller quantity products that have a very high manufactured value. Oftentimes there are products that must be sold by weight for commercial reasons and therefore this filling machine is the only choice. Examples of this type of filler for bulk products include cleaning chemicals, enzyme solutions, oils and other medium value products. High value products filled by these machines include specialty adhesives and paints, precious metals dissolved in acids, and other expensive specialty chemicals.
[0021] The operation of this type of filling machine is simple. The product bulk supply is pumped into a holding tank above a pneumatically operated valve. The valve opens and real time net weight information is monitored until the target weight is achieved. The valve simply shuts when the target weight is achieved. Accuracy of fills is accomplished by various “bulk and dribble” methods in the filling process so that overfills are avoided.
[0022] Volumetric Dosing Devices
[0023] There are also known in the art devices adapted for filling receptacles with a predetermined volume by volumetric control of the volume exiting the filling machine. Several such examples are disclosed in GB2379719, GB2111605 and GB2292574, all of which are concerned with a control volume provided with a working volume isolated from the control volume, and adapted to be reduced/increased by the introduction of an incompressible auxiliary material into the control volume.
[0024] Hazardous Location Liquid Filling Machines
[0025] Any of the machines outlined above can be built for Hazardous Location operation. Hazardous location means that there is risk of explosion or auto-ignition of the products being filled. Examples of products like this are alcohol, solvents, petroleum products, paints, etc.
[0026] Many of the manual and semi automatic versions of the types of liquid filling machines discussed above are inherently safe since they require no electrical operating systems. However, more sophisticated and higher output automatic machines using electrical systems must be built with intrinsically safe enclosures that are UL listed and conform to the National Electric Code as well as requirements of major insurance carriers. There are automatic liquid filling machines offered in the market with completely pneumatically controlled operating systems.
[0027] Corrosive Environment Liquid Filling Machines
[0028] As suggested above, time gravity fillers are often used for filling of corrosive products. But sometimes the products being filled are so aggressive that special construction methods are required. Harsh factory environments or where the product being filled can also be particularly aggressive on machinery. This includes not only chemical plants producing strong acids or bleach but also food plants using brine or sugar solutions in their products. In both cases, even the factory air alone contributes to the accelerated degradation of the machinery.
[0029] Machine integrity can be enhanced by using special powder and industrial polymer coatings on structural and other exposed machinery components. Also, whenever practical, substitution of chemical resistant plastics such as UHMW and Teflon are used in place of metal.
[0030] Not only are the frame components at risk in these environments but the fluid path materials must be specifically chosen for the types of products they come into direct contact with. For example, Kynar and Teflon fluid path materials may be used in a bleach filling machine because of their excellent resistance to the aggressive properties of bleach.
[0031] It should be noted that there is no ideal combination of materials in a filling machine when it comes to corrosive filling. Avoidance of some metal components is impossible particularly in the case of fasteners. The operator of this type of machinery should be prepared for stringent maintenance of these types of machines.
[0032] Amongst the most meaningful parameters of the dosing and packaging equipment influencing on the end-user's choice are: the accuracy, the operating speed, the control simplicity, the size and the price (the last parameter is a critical one for a majority of the end-users), and maintenance (daily and periodic care and cleaning).
SUMMARY OF THE INVENTION
[0033] The new method according to the present invention for cyclically portioning liquids and pastes by displacing required volume provides the technical base for a variety of “Volumetric Copying Devices” and/or “VCD” which will provide end-users with control simplicity, high accuracy and desired operating speed of packaging and the significantly smaller sizes and lower prices.
[0034] The object of the present invention is to provide this new volumetric method for portioning liquids and pasted products at a required rate of operating speed, for example, in the range of 60 portions per minute, and with a minimum excess of the product over the predetermined target volume in order to minimize “give-away” losses, or for otherwise best matching the predetermined target volume, including the cases then the target of a portion can be changed from cycle to cycle in preset limits, and at minimal manufacturing cost of the dosing machine.
[0035] According to the present invention, there is provided a method for volumetric displacement of a predetermined desired volume ΔV of target material from a first location to a second location, said method comprising the steps of:
(a) providing a rigid control volume having a volume V 0 accommodating a resilient volumetric member coaxially located therein having a target material chamber of volume V 1 confined by an inner surface thereof, and constituting said first location, and an auxiliary material chamber of volume V 2 confined between an outer surface of the resilient volumetric member and an inner surface of said rigid control volume; said control volume further comprising at least a target material outlet; (b) filling said target material chamber with said target material; (c) introducing a predetermined desired volume ΔV of an incompressible auxiliary material into said auxiliary material chamber to apply pressure to said resilient volumetric member, thereby increasing the volume of the auxiliary material chamber V 2 to V 2 ′=V 2 +ΔV and consequently reducing the volume of the target material chamber from V 1 to V 1 ′=V 1 −ΔV; and (d) allowing a predetermined amount ΔV of target material to exit the target material chamber through said target material outlet to said second location.
[0040] The term auxiliary material chamber may also be referred to hereinafter in the specification and claims as ‘control interstice’.
[0041] the term ‘target material’ as used herein the specification and claims denotes any flowable substance such as liquids, slurries, pastes, gels, and any such materials comprising a flowable material with particulate material dispersed therein. An unlimited number of examples may be provided such as Cheese products, dairy products, cosmetics, gravies, dips, sauces, oils, chemical lubricants and other substances.
[0042] Said method may be adapted for periodical operation, wherein said method further includes the steps of:
(e) closing said target material outlet; (f) withdrawing a predetermined volume ΔV of the auxiliary material from said auxiliary material compartment such that the compartments return to their initial volumes V 1 and V 2 ; and (g) repeating steps (a) to (d) above.
[0046] Hereinafter, the series of steps (a) to (f) will be referred to as a ‘stroke’.
[0047] In particular, the rigid control volume may have a nominal dimension D 1 and said resilient volumetric member may have a nominal dimension D 2 <D 1 , such that for a range of nominal dimensions D 1 <12″, the ratio
[0000]
R
=
D
1
D
2
[0000] between the nominal dimensions of the rigid control volume and the resilient volumetric member may be in the range of 1.5>R>1.1.
[0048] Said method may be also adapted for displacing through said target material outlet a different volume of target material on each stroke, thereby allowing
[0049] Said method may be used for the filling of receptacles with said target material, and may be employed, for example, in a filling line.
[0050] Said method may also be adapted for cleaning the control volume, wherein the method further includes the steps of:
(h) emptying the target material compartment from said target material; (i) providing a cleaning substance into said target material compartment; and (j) washing the target material compartment while periodically changing the volumes V 1 and V 2 using said auxiliary material.
[0054] It is worth noting that the cleaning operation, during which a cleaning agent is introduced into the target material chamber, is performed under an extensive amount of pressure, which attempts to ‘inflate’ the resilient volumetric member. However, due to the specific ratio R between the dimensions of the control volume and resilient volumetric member, the volumetric member is not allowed to ‘inflate’ to an extent damaging the mechanical integrity thereof, as its inflation is restricted by the rigid walls of the control volume.
[0055] The method of the present invention may also be adapted for performing a calibration/reset operation adapted for precisely controlling the initial volumes V 1 and V 2 of the respective target material chamber and auxiliary material camber, which may be applied by the following steps:
(k) providing a withdrawal device being in flow communication with the control interstice and adapted to withdraw material therefrom; (l) withdrawing material from the control interstice by said withdrawal device until the outer surface of said volumetric resilient member comes in contact with the inner surface of said rigid control volume; and
[0058] After completing the calibration steps above, the filling/dosing operation may be performed according to steps (a) to (d).
[0059] According to another aspect of the present invention there is provided a system adapted for performing the method according to the previous aspect of the present invention, said system comprising:
a rigid control volume formed with a target material inlet adapted for coupling to a target material supply, an auxiliary material inlet adapted for coupling to a supply line of an incompressible auxiliary material, and a target material outlet; a resilient volumetric member coaxially contained within said rigid control volume, and having a target material inlet and a target material outlet in fluid communication with the respective target material inlet and outlet of the rigid control volume; and
[0062] wherein the rigid control volume is divided into a target material chamber of volume V 1 defined between the target material inlet and outlet of the resilient volumetric member, and an auxiliary material chamber of volume V 2 defined between an outer surface of the resilient volumetric member and an inner surface of rigid control volume, said auxiliary material chamber being in flow communication with said auxiliary material inlet.
[0063] Said system may further comprise a target material supply in flow communication with the target material inlet of the control volume, an outlet assembly in flow communication with the target material outlet and adapted for monitoring the discharge of target material through to target material outlet, and an auxiliary material displacement mechanism in flow communication with the auxiliary material inlet and adapted for provision of the incompressible auxiliary material to the control interstice.
[0064] In particular, the rigid control volume may have a nominal dimension D 1 and said resilient volumetric member may have a nominal dimension D 2 <D 1 , such that for a range of nominal dimensions D 1 <12″, the ratio
[0000]
R
=
D
1
D
2
[0000] between the nominal dimensions of the rigid control volume and the resilient volumetric member may be in the range of 1.5>R>1.1.
[0065] It should be appreciated that the cross section of the rigid control volume and the resilient volumetric member is not limited to a circular shape, and may be any other polygon, in which case the dimensions D 1 , D 2 may refer to the diameter of the inscribing circle of the polygon.
[0066] The control volume may further be formed with a control outlet in fluid communication with the control interstice and comprise a pressure control arrangement in fluid communication with said control outlet, adapted for performing calibration/reset of the system, as well as monitoring the mechanical integrity of the resilient volumetric member.
[0067] The control pressure arrangement may comprise a pressure line extending from said control interstice, said pressure line being provided with a vacuum generator, a closable outlet and a sensor.
[0068] For example, during calibration of the system, the vacuum generator may be adapted to generate vacuum, whereby the resilient volumetric member begins to ‘inflate’, i.e. radially expand, whereby the outer surface thereof comes in contact with the inner surface of the rigid control volume. It is important to note that since the ratio R is chosen as specified above, the resilient volumetric member is prevented from deforming beyond the elastic area thereof.
[0069] In addition, the vacuum generator may be adapted for generating vacuum during operation of the system, slightly ‘inflating’ the volumetric resilient member, whereby, in the event of a rupture of puncture in the resilient volumetric member, the sensor is adapted to notify an operator of the system of a possible malfunction and the system may be brought to a halt.
[0070] In other words, a liquid branch of the volumetric dosing machine on two parts physically isolated each from other, one liquid part containing the dosed liquid product, and another—the lubricating oil only; as a result, the dosed product has no access to the moving parts of the pump that allows to raise sharply terms of its work and practically having excluded the intensive long time processes of the disassembly, cleaning, replacement of isolating rings, assembly, etc.; the additional increase in the terms of the work and the improvement of the quality of the work of the pump is due to occurrence of the contact of the moving parts of the volumetric dosing machine with the machinery oil;
[0071] The new function of the calculation of the optimum control signal moments for the volumetric dosing machine (from the controller of the line) are carried out for each cycle individually on the base of the adaptive mathematical model of the process of the dosing process, including the transfer function of transferring the set volume of the portion throughout the long lubricating oil tube; the adaptation of the mathematical model is carried out under the signals from the weight measuring device giving the information about the received real volume (weight) of the previous portion; the calculation of the new set volume in an air part of the pump is carried out also on the base of using the adaptive mathematical model by means of automated servo-driver of the pump volume adjusting device;
[0072] the new volumetric dosing machine is technologically divided into two parts; the part of the dosing machine situated on the stands of the packing line, and the part of the volumetric dosing machine with all auxiliary systems, including the servo-driver situated at a remote location from the packaging line stand, and situated separately in the electro—pneumatic control box of the packaging line; such configuration of the VCD Line allows a substantial reduction of the dimensions and, accordingly, its manufacturing cost;
[0073] the technology and the equipment of dividing the dosed liquid product from the lubricating oil, and the control of this dividing, are guarantees against transferring the lubricating oil in to the dosed product, and against transferring the dosed product to the moving parts of the pump, that enables to dose high-viscous liquid products including abrasive materials at excited environments;
[0074] the compact technological configuration of the new special module dividing the dosed product from the lubricating oil, in case of the penetration of the dosed product and/or the machinery oil into the dividing module during the dosing process, allows to replace the defected module with a new one during a very short time; better yet, the specified dividing module becomes an additional separate independent product or a spare part for the VCD Line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
[0076] FIGS. 1A to 1H are schematic representations of a system adapted for performing the method of the present invention, shown in different stages of displacement of a target material according to the present invention;
[0077] FIGS. 1I to 1M are schematic representations of the system shown in FIGS. 1A to 1H , shown in different stages of a cleaning process according to the present invention;
[0078] FIGS. 2A to 2J are schematic representations of stages of calibrating the system shown in FIGS. 1A to 1M ;
[0079] FIG. 3A is a schematic cross-section of a control volume used in the system shown in FIGS. 1A to 1M ;
[0080] FIG. 3B is a schematic longitudinal cross-section of the control volume shown in FIG. 3A ;
[0081] FIG. 4 is a schematic block diagram of the system shown in FIGS. 1A to 1M ; and
DETAILED DESCRIPTION OF EMBODIMENTS
[0082] With reference to FIGS. 1A to 1H , a filling system is shown, generally designated as 1 adapted for working in conjunction with a filling line L. The system comprises a control volume portion 10 , a target material storage 20 , an auxiliary material mechanism 30 , an outlet assembly 40 , a controller unit 50 , and a cleaning arrangement 60 .
[0083] The control volume portion 10 comprises a target material compartment 12 and an auxiliary material compartment 14 , sealingly separated from one another by a resilient diaphragm 16 adapted to deform so as to selectively change the volume of one compartment on the expense of the other compartment. The control volume 10 has a volume V 0 which is constituted at all times by the combined volume V 1 of the target material compartment 12 and volume V 2 of the auxiliary material compartment 14 .
[0084] The control volume 10 is formed with a first inlet port 13 located at a top end thereof and being in fluid communication with the storage 20 to receive a target material M T therefrom, a second inlet port 15 formed in the auxiliary material compartment 14 and being in fluid communication with the auxiliary material mechanism 30 to receive the auxiliary material M A therefrom, and an outlet port 17 at a bottom end thereof being in fluid communication with the outlet assembly 40 .
[0085] The resilient diaphragm 16 is in the form of a sleeve situated within the rigid control volume 10 , the arrangement being such that the resilient diaphragm 16 has a diameter D′ which is slightly smaller than the diameter D of the control volume 10 , such that there extends a control interstice 11 between the control volume 10 and the resilient diaphragm 16 (see FIGS. 3A and 3B ). The advantages of this gap will be discussed in detail with respect to the filling operation of the system 1 , with particular reference to FIGS. 2A to 2J .
[0086] The controller unit 50 comprises a stopper 52 located between the first inlet port 13 and the storage 20 , adapted to regulate the displacement of material from the storage 20 to the control volume 10 . The stopper 52 may assume an open position (shown FIG. 1A ) in which target material M T is free to displace from the storage 20 to the control volume 10 , and a closed position (shown FIG. 1D ) in which the stopper 52 prevents such displacement. It should be appreciated that the stopper 52 may also assume a plurality of intermediary positions between the open position and the closed position.
[0087] The auxiliary material mechanism 30 comprises an auxiliary material chamber 32 , a piston 34 adapted to linearly displace within the auxiliary material chamber 32 , and a fluid communication line 36 adapted to connect the auxiliary material chamber 32 with the second inlet port 15 of the control volume 10 .
[0088] The outlet assembly 40 comprises a central passage 42 , a deformable membrane 44 and two pistons 46 adapted for lateral displacement in order to apply pressure to the deformable membrane 44 , whereby the outlet assembly 40 may assume a first, open position in which the target material M T is free to displace along the passage 42 from the control volume 10 to the receptacles C of the filling line, and a second, closed position in which the membrane 44 is deformed to such an extent that the above displacement is prevented.
[0089] The filling line L is situated under the outlet assembly 40 , and comprises a conveyer belt B having positioned thereon a plurality of containers C 1 , C 2 . . . C n adapted to be filled with the target material M T .
[0090] At a first stage of the filling operation shown in FIG. 1A , the storage 20 is empty, the stopper 52 is in its open position, and the outlet assembly is also in its closed position.
[0091] At a second stage of the filling operation, shown in FIG. 1B , a target material M T is provided into the storage 20 , and due to the open position of the stopper 52 , the target material M T fills the control volume as well. In this position, the target material compartment 12 of the control volume 10 is fully filled with the target material M T , such that V 1 constitutes the majority of the volume V 0 of the control volume 10 (i.e. V 1 ≈V 0 ), and V 2 is approximately zero (i.e. V 2 ≈0). This position of the control volume 10 may be referred to as a filled position.
[0092] At a third stage of the filling operation, shown in FIG. 1C , the stopper 52 is displaced to its closed position such that no additional target material M T may displace from the storage 20 to the control volume 10 .
[0093] Thereafter, at a fourth stage of the filling operation, shown in FIG. 1D , the outlet assembly 40 is displaced into its open position and the piston 34 of the auxiliary material mechanism 30 begins to displace linearly within the chamber 32 so as to displace a certain volume of the auxiliary material M A into the auxiliary material compartment 14 of the control volume 10 . This displacement causes deformation of the resilient diaphragm 16 , thereby leading to an increase in the volume V 2 of the auxiliary material compartment 14 on the expense of a decrease in the volume V 1 of the target material compartment 12 . This change in volumes, in turn, leads to ejection of the target material M T contained within the control volume 10 through the passage 42 of the outlet assembly 40 and into one of the receptacles C.
[0094] Turning now to FIGS. 1E and 1F , at the next step of the filling operation, once a predetermined desired volume ΔV of auxiliary material M A has been displaced by the piston 34 , the control volume 10 assumes an emptied position, in which the target material compartment 12 assumes a decreased volume V 1 ′=V 1 −ΔV, and the auxiliary material compartment 14 assumes an increased volume V 2 ′=V 2 +ΔV.
[0095] Thus, the volume of the target material M T ejected into the receptacle C 1 is exactly the desired predetermined volume ΔV. At this stage, the pistons 46 of the outlet assembly 40 are displaced towards one another such that the outlet assembly 40 assumes its closed position.
[0096] At a following stage of the filling operation, shown in FIGS. 1G and 1H , the stopper 52 is displaced into its open position, and the piston 34 is displaced backwards to withdraw the auxiliary material M A from the auxiliary material compartment 14 . This withdrawal entails an increase in the volume of the target material compartment 12 to its original volume V 1 , whereby target material M T from the storage 20 is sucked into the control volume 10 .
[0097] Thus, the control volume 10 returns to a filled position, i.e. the target material compartment 12 is filled with the target material M T , and the volume distribution between the compartment 12 , 14 is again V 1 ≈V 0 , and V 2 ≈0. At this stage, the conveyer belt B of the filling line L progresses to the left so as to position an empty receptacle C 2 under the outlet assembly 40 , whereby the stages of the filling operation may be repeated.
[0098] The stages described above with reference to FIGS. 1A to 1H define a single stroke of the volume displacement system 1 .
[0099] It is appreciated that throughout the entire stroke performed by the system 1 , there is never any danger of mixture or contamination of the target material M T by the auxiliary material M A .
[0100] It is also appreciated that the desired volume ΔV discharged through the outlet assembly 40 into the receptacle C is highly accurate due to the simple control over the piston 34 .
[0101] In addition, it is noted that even in its most deformed position, the resilient diaphragm 16 leaves a passage path for the target material M T . This path facilitates maintaining the quality of the target material M T contained within the control volume 10 , for example, yogurts or clustery slurries do not become crushed or ground. Furthermore, unlike in regular piston systems, in the present invention, there is no compression of the target material M T , wherein when the target material M T is an aerated material, i.e. a material containing a considerable amount of trapped air, the majority of air remains within the target material M T , and does not escape therefrom.
[0102] Turning now to FIGS. 1I to 1M , a cleaning operation of the system 1 is shown at different stages of operation thereof.
[0103] At a first stage of the cleaning operation, shown in FIGS. 1I and 1J , the stopper 52 and outlet assembly 40 assume their open positions in order to allow draining of the entire target material M T from the control volume 10 and the storage 20 . A specially designed suction tube 80 is adapted to attach to the passage 42 of the outlet assembly 40 and drain the target material M T .
[0104] At a following stage of the cleaning operation, shown in FIG. 1K , it is observed that although the target material M T is drained, there remains a residual of the target material M T on the side walls 22 of the storage 20 , and on the inner side of the resilient diaphragm 16 , i.e. within the target material compartment 12 .
[0105] Thus, at the next stage of the cleaning operation, shown in FIG. 1L , the cleaning arrangement 60 is adapted to emit into the storage 20 and control volume 10 a cleaning agent 64 through a cleaning head 62 thereof. The cleaning agent 64 is sprayed by the cleaning head 62 over the inner walls 22 of the storage and is drained down through to control volume 10 into the suction tube 80 .
[0106] During this cleaning operation, as shown in FIG. 1M , the auxiliary material mechanism 30 may operate periodically at an increased rate, i.e. the piston 34 being moved pack and forth repeatedly at an increased rate, causing vibration/rapid deformation of the resilient diaphragm 16 so as to facilitate better cleaning of the control volume 10 .
[0107] Turning now to FIGS. 2A to 2J , the system 1 is shown fitted with an additional pressure regulating mechanism 90 working in conjunction with the auxiliary material mechanism 30 , during various stages of preparation and of the filling operation of the system 1 .
[0108] The pressure regulating mechanism 90 comprises a storage tank 91 being in fluid communication with the piston chamber 32 . It is observed that the piston chamber 32 is divided by the piston 34 into a front portion 32 a and a rear portion 32 a . The tank 91 is connected to the rear portion 32 a via a rear line 92 and to the front portion 32 a by the front line 94 .
[0109] The pressure regulating mechanism 90 further comprises a discharge line 96 connecting the auxiliary material compartment 14 with the outside environment through an additional outlet port 19 formed in the control volume 10 . The discharge line is fitted with a vacuum generator 98 adapted for withdrawal of the auxiliary material M A through the line 96 , and a sensor 99 adapted to monitor the pressure within the line 96 .
[0110] Each of the lines 92 , 94 and 96 are fitted with respective valves 95 and 97 , adapted to be selectively opened/closed so as to allow/prevent fluid communication between the tank 91 and the line 36 , and between the outlet port 19 and the outside environment.
[0111] With particular reference to FIG. 2A , the system 1 is shown during an initial stage of operation, when the storage 20 is empty of target material M T , and the auxiliary material mechanism 30 is empty of auxiliary material M A . It is noted that both portions 32 a , 32 b are empty, the valve 95 is in its open position and the valve 97 is in its closed position.
[0112] At the following stage, shown in FIG. 2B , the storage tank 91 is filled with the auxiliary material M A , and since the valve 95 is in its open position, the auxiliary material M A flows through the lines 92 and 94 to fill both portions 32 a and 32 b of the chamber 32 .
[0113] From this stage, as shown in FIGS. 2C and 2D , the valve 97 is opened, and the vacuum generator 98 begins it operation, sucking the auxiliary material M A through line 96 until the chamber 32 , line 36 , auxiliary material compartment 14 and line 96 are filled with the auxiliary material M A . Thereafter, the valves 95 and 97 are closed, and effectively all the lines 92 , 94 , 96 and chamber 32 only contain the auxiliary material M A and no excess gas, e.g. air.
[0114] In addition, during this stage, calibration of the system may be performed, during which the vacuum generator 98 generates vacuum so as to ‘inflate’ the resilient diaphragm 16 , causing the outer surface thereof to come in contact with the inner surface of the control volume 10 . In this position, the exact volume of the target material chamber 12 is known to an operator since V 1 =V 0 , and filling of the storage 20 with the target material M T may be performed, thereby fully preparing the system 1 for performing the filling operation.
[0115] At the following stage, shown in FIGS. 2E and 2F , the piston 34 is displaced forwards so as to deform the resilient diaphragm 16 , thereby pushing the target material M T within the storage 20 upwards, and the displaces backwards, letting to target material M T drop back into the control volume 10 . This operation may be performed several times and is useful for tighter arrangement of the target material M T within the control volume 10 , and also makes sure that the entire volume of the target material compartment is filled with the target material M T .
[0116] At the following stages shown in FIG. 2G to 2J , the system performs the filling operation, equivalent to that described with respect to FIGS. 2A to 2H .
[0117] It is important to note that due to the pressure regulating arrangement 90 , the piston 34 is completely immersed in the auxiliary material M A , and the lines 92 , 94 and 96 are completely filled with the auxiliary material M A , thereby preventing excess gas such as air to be trapped within the system 1 and effecting volumetric calculations.
[0118] It is also appreciated that the pressure regulation mechanism 90 is also adapted to function as a security mechanism in the case that the resilient diaphragm 16 is punctured. In such a case, the vacuum generator 98 is adapted for generating vacuum, thereby preventing any of the auxiliary material M A from penetrating into the target material compartment 12 .
[0119] FIG. 4 diagrammatically illustrates one of the possible forms of the block-diagram of the apparatus constructed for realizing the invented method for the volumetric cyclically portioning of liquids and pasted products for the operating speed of 30 portions per minute for one technological sub line for relatively small sizes of the portions, for example, 100-200 ml.
[0120] It is to be understood that the foregoing drawing, and the description below, is provided primarily for purposes of facilitating understanding the conceptual aspects of the invented method and various possible embodiments thereof. In the interest of clarity and brevity, no attempt is made to provide more details than necessary to enable one skilled in the art, using routine skill and design, to understand and practice the described invention. It is to be further understood that the embodiments described are for purposes of example only, and that the invented method is capable of being embodied in other forms of block-schemes, diagrams and applications than described herein.
[0121] The main parts of the embodiment of the FIG. 4 and its connection are as follows:
[0122] 108 is a device for supplying empty containers ( 127 ) on the conveyor ( 106 ) mounted on the packaging line body ( 138 ).
[0123] 126 —a driver of the conveyor ( 106 ) serving the movement of the containers ( 105 ) in the direction ( 111 ) and for stopping them on ( 105 - 1 ), for receiving the portion of the dosed product ( 105 - 2 ) and for a control weighing at a weighing device 107 and 105 - 3 for closing and labeling by device 128 .
[0124] 134 is a direction which the containers are exiting from a line or conveyor 106 .
[0125] 101 is a receiving bunker for a product to be dosed.
[0126] 136 is a new volumetric dosing machine consisting of a volume forming and control device ( 125 , 129 , 130 , 131 , 133 , 116 ) and a volume copying and dosing device ( 102 , 109 , 125 , 123 ).
[0127] 125 is a liquid chamber consisting of a lubricated oil, connected to stainless steel tubes to transfer the oil ( 110 ) equipped by a check valve ( 103 ) and an outlet port ( 122 ) with a check valve ( 139 ).
[0128] 110 - 1 is a lubricated oil in the volumetric control device.
[0129] 110 - 3 is a lubricated oil in the volume copying device.
[0130] 110 - 2 is a lubricated oil in the transferred tube.
[0131] 110 is a stainless steel tubes which transfer the lubricated oil and provide the long distance control of the dosed portion volume.
[0132] 129 is a lubricated oil piston.
[0133] 118 is a direction of a motion for creating a portion volume and for filling a container ( 105 - 1 ), down for creating the portion volume.
[0134] 130 is a vent chamber with a vent port ( 117 ).
[0135] 133 is an air chamber (the refill stroke).
[0136] 116 is an air piston mechanically connected ( 131 ) with a lubricated oil piston ( 129 ).
[0137] 137 is an air chamber (discharge stroke) with a vent port ( 117 ).
[0138] 135 is a thread seal with automatically adjusted bolt ( 120 ) mechanically connected with the servo-drive ( 121 ).
[0139] 121 is a controlled servo driver for regulating the volume of a device 136 with control unit 132 .
[0140] 115 is a “Up/Down” dose adjustments to set product volume (“Down” for receiving more larger portion volume, and “Up” for receiving less portion).
[0141] 113 is an air pressure for forming a portion volume.
[0142] 114 is an air pressure for filling the container ( 105 - 1 ).
[0143] 102 is an dosing liquid chamber of the volume copying device, equipped with inlet ( 104 ) and outlet ( 104 ) tubes and check valves ( 103 ), accordingly.
[0144] 109 is a chamber structure to divide between an dosing liquid chamber and the volume copying device 110 - 3 . For example: in the form of a “two” membranes device divided by distillated water for instance, and equipped with a control device ( 123 ) for an operative control of dividing an dosing product in a dosing liquid chamber ( 102 ) from a lubricated oil in a liquid chamber ( 125 ).
[0145] 124 is a computerized control system (for example, a PLC) of a VCD Line receives information from a weighing device ( 107 ) and from controlling unit ( 123 ), and sends outputting control commands to check valves ( 103 and 139 ), the inputs of an air pressure ( 113 and 114 ), the conveyor driver ( 126 ) and a control unit ( 132 ) of a servo-driver ( 121 ).
[0146] Dynamic Operations of Embodiments
[0147] The driver ( 126 ) of the conveyor ( 106 ) moves the containers ( 105 ) in the direction of its motion ( 111 ) and stops them at 105 - 1 (for receiving a portion of the dosed product), 105 - 2 (for the controlled weighing on the weighing device 107 ) and 105 - 3 (for closing and labeling) by the closing and labeling device 128 .
[0148] During the motion of the conveyor ( 106 ), the volumetric dosing machine ( 136 ) is preparing a portion (of a dosed product) closed to the targeted volume. The movements within the chambers— 102 , 109 , 125 , 130 , 133 and 116 are controlled by the reciprocating action of the pump's shaft and the piston assembly. The assembly is operated and controlled by a 4-way air valve which alternately introduces and exhausts the air pressure on both sides of the air piston 116 . The 4-way valve would receive its on-off electric signal from the computerized control system 124 . This action also causes the lubricated oil piston ( 129 ) to reciprocate.
[0149] On the down stroke of the lubricated oil piston 129 a vacuum is created in the lubricated oil chamber 125 of the volume forming part of the dosing machine 136 which transferred throughout the lubricated oil tube ( 110 ) in to the lubricated oil chamber 125 of the coping part of the dosing machine 136 , and a vacuum is created in the dividing and volume coping liquid chamber 109 and in the product dosing liquid chamber 102 .
[0150] The product dosing liquid chamber 102 is filled automatically by opening upper check valve 103 (at closed lower check valve 103 ). On the up stroke the product in a chamber 102 is pressurized by the pistons movement and by opening the lower check valve 103 (at closed upper check valve 103 ), and the dosed product is discharged out the volumetric dosing machine 136 .
[0151] The developed volumetric dosing machine 136 can be classified as a positive displacement pump with an automatic adjustment by the servo-driver 121 and the control unit 132 . All operations of the dosing and automatic adjustments are provided by the computerized control system 124 (for, example, realized on the base of PLC) of the VCD Packaging Line. | Provided is a method for volumetric displacement of a predetermined desired volume ΔV of target material from a first location to a second location. The method including: (a) providing a rigid control volume having a V 0 accommodating a resilient volumetric member coaxially located therein having a target material chamber of volume V 1 . The target material chamber is confined by an inner surface thereof, and constitutes the first location. The control volume V 2 confined between an outer surface of the resilient volumetric member and an inner surface of the rigid control volume. The control volume further includes at least a target material outlet; (b) filling the target material chamber with the target material; (c) introducing a predetermined desired volume ΔV of an incompressible auxiliary material into the auxiliary material chamber to apply pressure to the resilient volumetric member. Thus, there occurs increasing of the volume of the auxiliary material chamber V 2 to V 2′ =V 2 +ΔV and consequently reducing of the volume of the target material chamber from V 1 to V 1′ =V 1 −ΔV; and (d) allowing a predetermined amount ΔV of target material to exit the target material chamber through the target material outlet to the second location. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to stacked semiconductor device assemblies and packages, as well as to associated assembly and packaging methods. More particularly, the invention pertains to multi-chip assemblies and packages with good thermal properties and dense chip packaging.
BACKGROUND
[0002] The dimensions of many different types of state of the art electronic devices are ever decreasing. To reduce the dimensions of electronic devices, the structures by which the microprocessors, memory devices, other semiconductor devices, and other electronic components of these devices are packaged and assembled with carriers, such as circuit boards, must become more compact. In general, the goal is to economically produce a chip-scale package (CSP) of the smallest size possible, and with conductive structures, such as leads, pins, or conductive bumps, which do not significantly contribute to the overall size in the X, Y, or Z dimensions, all while maintaining a very high performance level.
[0003] Conventionally, semiconductor device packages have been multilayered structures having one, two or more chips stacked above each other. The major problems of such systems are of thermal nature since it was not possible to dissipate the heat efficiently in these systems. Further problems are also signal falsification and wiring problems. One example of the state of the art is given in FIG. 1 . In this example four chips are stacked above each other to form a package, so that this arrangement will also be referred to as a one-four-stack arrangement. The disadvantage of this package is very poor heat dissipation, long signal routes, possible inter-crossing of the connections, routing problems and cross talk. A further disadvantage of the package as shown in FIG. 1 is the elevation of the entire package.
[0004] Furthermore, WO 96/13855 discloses an arrangement in which two chips are provided on the opposite sides of a lead plate.
[0005] For these and other reasons there is a need for the present invention.
[0006] Following terms will be used in following:
[0007] The semiconductor integrated circuit chip will be in following referred to as a “chip”;
[0008] In the packaging process a chip may also be referred to as a “die”;
[0009] The term stacked means an arrangement where two objects are placed above each other;
[0010] “stacked in parallel” means that the chips are stacked essentially exactly above each other, wherein a top surface of one chip is facing a bottom surface of the chip arranged above it;
[0011] “stacked anti parallel” means that the chips are stacked essentially exactly above each other, wherein a top surface of one chip is facing a top surface of the chip arranged above it or wherein a bottom surface of one chip is facing a bottom surface of the chip arranged above it;
[0012] “a bottom surface of a chip” is a surface which is closer to the printed circuit board; the bottom surface is also the surface of the chip which is provided with pads connected to the printed circuit board. “a top surface of a chip” is a surface opposite to the bottom surface.
SUMMARY
[0013] The present invention provides a multi-chip package and method of making a multi-chip package. In one embodiment, the multi-chip package includes at least four of spaced semiconductor integrated circuit chips mounted on a printed circuit board, consisting of the first pair of the semiconductor integrated circuit chips and the second pair of the semiconductor integrated circuit chips. The chips of the first pair of the semiconductor integrated circuit chips are arranged substantially parallel and the chips of the semiconductor integrated circuit chips of the second pair are arranged substantially stacked over the chips of the first pair of the semiconductor integrated circuit chips.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate the embodiments of the present invention and together with the description serve to explain the principles of the invention. Other embodiments of the present invention and many of the intended advantages of the present invention will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.
[0015] FIG. 1 illustrates a cross view example of a multi-chip package assembly according to the prior art.
[0016] FIG. 2 illustrates a cross view example of a multi-chip package assembly according of the present invention.
[0017] FIGS. 3-5 illustrate various examples of a multi-chip package of the present invention when attached to a printed circuit board and some processes in their manufacturing.
DETAILED DESCRIPTION
[0018] In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
[0019] The present invention provides higher density organization of a plurality of semiconductor integrated circuit chips wherein the semiconductor integrated circuit chips are arranged such that good thermal properties and short signal times can be achieved.
[0020] The present invention also provides an assembly which effectively dissipates heat generated during normal operation. Efficient thermal management increases the operational life of the module, and improves reliability by eliminating the effects of elevated temperature on the electrical characteristics of the integrated circuit and packaging. When packages are not stacked, heat from the embedded integrated circuits, generated through normal operation, is primarily dissipated by convection from the package's external surfaces to the surrounding air. When modules are formed by stacking packages, the buried packages have reduced surface area exposed to the air so that the heat dissipation is reduced.
[0021] According to the present invention, a multi-chip package and interconnect assembly is provided which allows short interconnection between chips as well as good heat conduction from the chips to the package exterior. The transit time of signals between chips is typically about 30-40% than less that of using individual packages. Furthermore, heat generated during the operation of the chip can be efficiently dissipated. According to one embodiment of the present invention there are provided two stacks of chips, wherein each stack consists of two chips and not of four as in the prior art. Even though the surface of the arrangement is somewhat increased, due to the possibility to arrange a heat sink in between the chips and to connect the chips in a much shorter manner, the arrangement of the present invention is superior to the one of the prior art. The two-two-stack-arrangement of the invention enables a better signal properties than the one-four-stack of the prior art. The routing between the chips can further be optimized by providing a simpler pin allocation so that it is possible to completely avoid the wiring intercrossing.
[0022] In one embodiment, the present invention provides a package having at least four chips wherein the four chips are divided into the first pair of chips and the second pair of chips, wherein the first pair of chips are arranged essentially in parallel in the XY plane and second two pair of chips are stacked in parallel or anti-parallel with regard to the first pair of chips. It is to be noted that the reference to the XYZ-planes is only for the purpose of describing the special arrangement of the chips is not intended to be limiting for the arrangement of the present invention. For the purposes of simplicity XY plane will be regarded as the plane of the portion of the printed circuit board onto which two chips are provided.
[0023] In one embodiment, between the first pair of chips and/or the second pair of chips at least one heat sink is provided which is thermally connected to at least the first and/or the second pair of chips.
[0024] In another embodiment a single heat sink is provided, which is arranged between the first and the second pair of chips, wherein the heat sink is thermally connected to both the first and the second pair of chips.
[0025] In a preferred embodiment of the invention a first and a second heat sink are provided, wherein the first heat sink is thermally connected to the first and the second heat sink is thermally connected to the second pair of chips.
[0026] In a preferred embodiment of the invention the packaging of the chip are preformed in a ball grid arrays design, which are used to connect the package to a printed circuit board (PCB).
[0027] Turning now to the figures and, more particularly, FIG. 2 illustrates a cross view example of a first embodiment with multi-chip package assembly 100 according to the present invention.
[0028] As it can be seen from FIG. 2 , chip 1 and chip 4 form the first pair of chips, and chip 2 and chip 3 form the second pair of chips. The same applies throughout the description of the Figures.
[0029] According to FIG. 2 , the second pair of chips is stacked above the first pair of chips in an anti-parallel above each other. In the anti-parallel manner means in this case the top surface 11 of chip 1 for example is viewing the top surface 12 of chip 2 . The same applies to the top surface 13 of chip 3 and the top surface 14 of chip 4 .
[0030] Chips 1 , 2 , 3 and 4 are interconnected by means of wiring means 20 , which connect pads 40 of chips 1 , 2 , 3 and 4 . Between chips 2 and 3 as well as between chips 1 and 4 heat sinks 30 and 31 are provided.
[0031] FIGS. 3 a and 3 b illustrate one preferred embodiment of the present invention. In this embodiment chips 1 , 2 , 3 and 4 are arranged in such a way that all four chips are in a thermal contact with heat sink 30 . A method of manufacturing the arrangement of FIG. 3 b is schematically illustrated in FIG. 3 a.
[0032] As it can be see from FIG. 3 a, chips 2 , 3 , 4 and 1 are mounted in this order on printed circuit board (PCB) 5 . Section 6 of printed circuit board 5 on which chips 2 and 3 are mounted is connected to section 7 of printed circuit board 8 , on which chips 4 and 1 are mounted by means of flexible printed circuit board 9 . Between chips 2 and 3 , and 4 and 1 routing means or bonds 21 are provide in order to electrically connect chips 2 , 3 , 4 and 1 . By folding flexible printed circuit board 9 at 180° in such a way that the top surface of chips 2 / 3 face the top surface of chips 1 / 4 it is possible to arrange chips 2 / 3 , which form the first pair of chips in an anti-parallel manner with the chips 1 and 4 so that top surface 11 of chip 1 faces top surface 12 of chip 2 . The same applies to top surfaces 13 of chip 3 and top surface 14 of chip 4 respectively.
[0033] Thereafter, heat sink 30 can be introduced in such a manner that a thermal connection between chips 1 , 2 , 3 and 4 with heat sink 30 can be established. By way of example it is also illustrated how printed circuit board 4 is arranged with balls 50 .
[0034] FIG. 4 b illustrates another preferred embodiment of the present invention. In this embodiment chips 1 , 4 , 3 , and 2 are arranged anti-parallel to each other and are facing outwards and so that it is possible to obtain an arrangement without having to provide a heat sink since the heat exchange between the chips and the ambient environment is possible.
[0035] A method of preparation of this embodiment is schematically illustrated in FIG. 4 a. As it can be see from FIG. 4 a, chips 1 , 4 , 3 , and 2 are mounted in this order on printed circuit board (PCB) 50 . Section 60 of printed circuit board 50 on which chips 2 and 3 are mounted is connected to section 70 of printed certain board 50 , on which chips 4 and 1 are mounted by means of flexible printed circuit board 90 . Between chips 2 / 3 , and 4 / 1 routing means or bonds 21 are provide in order to electrically connect chips 1 , 4 , 3 , and 2 .
[0036] By folding flexible printed circuit board 90 at 180° in such a way that the bottom surfaces of chips 1 / 2 , and 3 / 4 face each other it is possible to arrange chips 1 and 2 , and 3 and 4 in an anti-parallel manner so that top surface 41 of chip 1 faces top surface 42 of chip 2 . The same applies to top surfaces 13 of chip 3 and top surface 44 of chip 4 respectively. In this manner an subassembly 60 can be manufactured which can then be connected with a PCB with usual means.
[0037] Even though it is not absolutely necessary in this embodiment a heat sink (not illustrated) can also be introduced in such a manner that a thermal connection between chips 1 / 2 and/or 3 / 4 with the heat sink can be established.
[0038] FIG. 5 b illustrates another preferred embodiment of the present invention. In this embodiment chips 4 / 1 and 3 / 2 are arranged in a parallel manner. A method of preparation of this embodiment is schematically shown in FIG. 5 a.
[0039] As it can be seen from FIG. 5 a, chips 3 and 2 as well as chips 4 and 1 respectively are mounted separately on a printed circuit board. By means of ball grid arrays it is then possible to connect the printed board section on which chips 3 / 2 and 4 / 1 respectively are mounted.
[0040] While the invention has been described in terms of several (example) preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.
[0041] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof. | A multi-chip package and method is disclosed. In one embodiment, the multi-chip package includes at least four of spaced semiconductor integrated circuit chips mounted on a printed circuit board, consisting of the first pair of the semiconductor integrated circuit chips and the second pair of the semiconductor integrated circuit chips. The chips of the first pair of the semiconductor integrated circuit chips are arranged substantially parallel and the chips of the semiconductor integrated circuit chips of the second pair are arranged substantially stacked over the chips of the first pair of the semiconductor integrated circuit chips. | 7 |
RELATED CASES
This application is a continuation-in-part of copending application Ser. No. 805,244, filed June 9, 1977, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the identification of the mold in which a vessel made from an optically transparent material has been molded. The mold in which the vessels are molded has an individual marking suitable for imprinting onto the vessel comprising relief-like elements disposed on a circular path.
In the manufacture of an article in a press mold, casting mold or blow mold, the deficiencies and errors of the mold are transferred onto the article. The result is, especially in manufacturing installations equipped with a number of identical molds and possessing a high production rate, that two important problems arise: the identification of that mold in which a specific article suffering from a defect was molded and the sorting out of all the articles which have been made in this mold, before the defective article was recognized or in the period between recognition of the defective article and replacement of the corresponding mold. The solution of these problems is especially important in modern installations for the production of glass vessels. The molds utilized in such installations are subjected to exacting thermal conditions and high mechanical loads and exhibit a correspondingly high rate of wear. Furthermore, such installations are equipped with a number of identical molds and are operated at a high production rate. Since it is only possible for the vessels to be examined for possible errors after they have passed through a tempering furnace, a large number of vessels have usually been molded in a defective mold, before the defect is discovered.
In order to solve both problems, the molds are furnished with a marking, which is transferred onto every article molded in them. This marking may simply be an ordinal number. A known device for reading the ordinal number designating the mold on a glass vessel is described in French patent application No. 74 21259 (AB Platmanufaktur). This device is adapted for reading ordinal numbers which are represented in a digital code. The individual code elements are constituted as dash-shaped, relief-like projections, which are disposed along a peripheral circle and preferably on the bottom surface of the vessel. To read them, at least one part of the peripheral circle is illuminated. The relief-like projections of the code elements then cause both the light passing through the vessel wall and also the light reflected from the vessel wall to be diffracted more intensely than that from a plane vessel wall. To read the code, the illuminated vessel is rotated about the center of the circle in front of a stationary reading device, and the changes in illumination of the reading device caused by the code elements are converted into electrical signals. In order to distinguish the illumination changes produced by the code elements from those which, for example, are caused by other markings formed on the vessel wall by mold joints or irregularities in the vessel wall, the evaluating device connected to the reading device is controlled by a synchronizing generator. For the synchronizing generator, a signal generator may be used, which generates synchronizing impulses which are proportional to the rotational speed of the drive apparatus for the vessel.
A preferred use of this device in the sorting line of an installation for manufacturing glass vessels is described in U.S. Pat. No. 3,923,158 (AB Platmanufaktur). In this use, the output from the device and the output from at least one test device of the sorting line are connected to associated inputs of a recording device. As soon as one of the test devices detects an unacceptable fault or an inadmissable number of faults, the ordinal number molded on the defective vessel and simultaneously or previously read by the reading device is indicated by the recording device and is stored or printed out optionally as desired.
The above-described device possesses a number of disadvantages, which severly restrict its practical use.
The evaluating circuit can only evaluate the read signals correctly when the code elements to be read pass before the reading device synchronously with the synchronizing impulses. For this to occur, two conditions must be satisfied. Firstly, the rotational speed of the vessels must coincide exactly with the rotational speed of the drive mechanism which triggers the signal generator, that is to say the vessel must not be subject to any slip relative to the drive device. This requirement cannot in practice be fulfilled with the high throughput speeds and rotational speeds encountered in the measuring and testing stations of a modern sorting line. Secondly, the angular interval between the code elements on the peripheral circle of the vessel must stand in an exactly defined relationship to the angular intervals between the markings utilized for triggering the signal generator and situated on the drive device. This requirement can only be satisfied in new molds. On account of the exacting thermal conditions and mechanical loading of the molds already mentioned, these molds are subject to unavoidable wear and small changes in shape, which adversely affect the angular interval between the code elements. Independently of the quality of the mold, changes in angle between the code elements can also be caused by uneven expansion and contraction of the vessel during tempering.
In the device described, the relief-like molded code elements are utilized as optical lenses, which image the light source upon the photoelement of the reading device. This necessitates a relatively high degree of accuracy in the shape of each code element, which cannot however be guaranteed on account of the wear of the molds already referred to.
Furthermore, in this device, the reading device is illuminated with practically parallel light, so long as there is no code element in the light path between the source and the reading device. This basic illumination is dependent upon the color of the glass of the vessel and the thickness of its wall, and the reading device accordingly produces a variable base signal, upon which the signal generated by a code element is superimposed. The absolute value of the two signals is therefore dependent not only upon the illumination of the reading device by a code element, but also upon the fluctuations in the base signal. The absence of a constant reference signal, against which the read signals can be set in a comparative relationship, renders the evaluation of the signals difficult and can indeed make this evaluation impossible.
SUMMARY OF INVENTION
The present invention has for its object an improved identification of the mold in which a vessel, manufactured from optically transparent material, is molded.
Another object of the present invention is to overcome the disadvantages described above.
In accordance with one aspect of the invention, the vessel is provided with a plurality of marks disposed about a path on the wall of the vessel. There is a first set of marks disposed above the path and a second set disposed below the path. One of the first or second sets contains code marks for providing an indication of the mold, and the other set contains timing marks suitable for the sequential reading of the code marks.
According to another aspect of the invention, the method of identifying the mold in which the vessel having the markings described above was molded includes rotating the vessel about the center axis of the path, illuminating the marks by a light path as the vessel is rotated and evaluating the diffraction of light caused by the marks, and generating time impulses in response to the evaluation of the timing marks for sequential reading of the code marks.
The present invention also contemplates an apparatus for identifying the mold in which the vessel, described above, was molded. The apparatus includes means for rotating the vessel about the center axis of the path, means for generating a light beam orientated substantially perpendicular to that portion of the vessel wall which is furnished with the marks as the vessel is rotated, and reading means disposed opposite to said means for generating a light beam, said reading means including means for reading said code marks and means for reading said timing marks, and means for converting the change in illumination caused by the presence of a mark into an electrical signal.
With this new method, it is ensured that the code elements or marks pass in front of the reading device synchronously with the synchronizing impulses, independently of what rotational speed the vessel may possess relative to the drive device, because the marking contains code elements and timing marks. This synchronizing is not adversely affected by the aging of the mold or by irregular contraction of the glass during tempering, because any possible change in the distance between successive code elements is compensated by an equal change of the distance between the associated timing marks.
According to a preferred embodiment, a reading device is used, for the evaluation of the diffraction of the light caused by the elements or marks of the marking, which is so disposed and constructed that, in the absence of an element or of a mark in the light path it is illuminated and, when an element or a mark passes through the light path it is darkened.
The use of this new reading device makes it possible for the signals read to be compared with a constant reference voltage and thus for the signals read to be separated with minimal complication and optimal reliability from the output signal generated by the reading device.
DESCRIPTION OF THE DRAWINGS
The invention is now described with the assistance of Figures in relation to a preferred example of embodiment. The Figures show:
FIG. 1 a lateral view of the lower part of a glass vessel with one form of embodiment of the new marking;
FIG. 2 a partial section along I--I through the lower part of the vessel of FIG. 1;
FIG. 3 another embodiment of the new marking;
FIG. 4 a diagrammatic plan on the preferred device for carrying out the method of this invention and the block diagram for the reading device and the electronic evaluation device;
FIG. 5 a perspective view of a form of embodiment of the light stop block incorporated in front of the reading device;
FIG. 6 a diagrammatic representation of the illumination of a photodiode before and during the passage of a marking;
FIG. 7 a preferred form of embodiment of the new marking;
FIG. 8 a light stop block which can be used for reading marking shown in FIG. 7;
FIG. 9 a lateral view of a light source and of the light stop block of FIG. 8 with associated photodiodes during reading of the marking;
FIG. 10 a diagrammatic plan view of the embodiment intended for reading the markings in incident light;
FIG. 11 a diagrammatic view of the light reflected from a code element; and
FIG. 12 a corresponding illumination of the associated photodiode.
DETAILED DESCRIPTION
FIG. 1 shows the lower part of a glass vessel 10, the bottom turned-in part of which possesses a marking 11. The individual marks are disposed in two horizontal rows, the first row of which, comprising marks 12-15, is disposed above a circular path 17 and the second row, comprising marks 19-24, below this circular path. The marks project from the wall of the glass vessel as shown in FIG. 2 and are oval in plan and have a circular arc cross-section in the horizontal direction. The marks are disposed in the bottom turned-in part of the vessel, that is set back from the maximum vessel diameter, which prevents the marks from being damaged when vessels are in contact with each other. On account of their shape, the marks act like optical lenses, diffracting the light passing through them.
The example of a marking shown in FIG. 1 contains, in the row below the circular path 17, the four marks 20 to 23, which are used as timing marks. These marks are provided for producing the synchronizing impulses, which regulate the reading device and evaluating device yet to be described. The marking also comprises, above the circular path and especially vertically above the timing marks, only two marks 13, 14, used as code elements. The indicated position of the two marks 13, 14 used as code elements, relative to the timing marks 20 to 23 corresponds to the number 5 in the BCD code (0, 1, 0, 1). Finally, in the marking shown, a further pair of marks 19, 12 and 24, 15 is provided to the right and left of the timing marks, one mark of each pair being below and one above the circular path 17. Each of these pairs of marks is provided for generating a starting signal, which activates the synchronizing generator, reading device and evaluating device. The two pairs of marks are disposed on the two sides of the true marking, so that the starting signal is produced before the timing marks and code elements enter the reading device, independently of the rotational direction of the vessel.
The marking illustrated as an example enables the numerals 1 to 10 to be represented in BCD code. In order to increase the range of numerals and for example to constitute the numbers 0 to 99, it is possible simply to arrange two tetrads one after the other. This would mean in practice that, instead of the four timing marks shown, eight such marks would need to be used with one field for a code element associated with each timing mark. It will be understood that in the same way it is also possible for three or more tetrads to be utilized for representing still larger numerals.
Instead of the marks shown, which are oval in plan, it is of course also possible for marks which are circular in plan to be used. Because the marks are used as optical lenses and are more effective the larger their cross-section, the marks are preferably formed as dash-shaped marks, which act as cylindrical lenses. FIG. 3 shows a marking comprising such dash-marks, the dash-marks corresponding to the marks shown in FIG. 1 being referenced with the same symbol plus an apostrophe. With this marking system, marks of the lower and upper row situated vertically one above another are simply joined together to a single dash-mark of double the length.
FIG. 4 shows diagrammatically a plan view of a preferred embodiment of an apparatus for carrying out the new method and also the block diagram for the reading device and the electronic evaluating device. The apparatus cooperates with a rotational device, not shown, which is disposed in the path of a sorting line and in which a vessel 10 is rotated at least once about its vertical axis of symmetry 26. Rotational devices of this type are known to every person skilled in the art and described, for example, in Swiss Pat. Nos. 548,599 and 570,912. An illuminating device is disposed on one side of the rotational device and comprises a light source 30 and a condenser lens 31, which generates a practically parallel light beam. A light stop block 33 is mounted on the other side. The light stop block contains six channels 34 to 39 (FIG. 5). These channels extend practically in the same direction as the light beam produced by the illumination device 30, 31. The cross-section of each channel is approximately equal to the cross-section, situated in the same direction, of an individual mark of the marking. The six channels are disposed in two superimposed rows, each of which contains three channels. The end of each channel nearest the light source is open. The entry end of a photoconductor 42 to 47 is introduced into the opposite end of the channels. The photoconductors preferably consist of a fibre optic. The outlet end of each photoconductor is connected to an associated photodiode 50 to 55. The signal outputs of the photodiodes 50 and 54, which are connected by the photoconductors 42 and 46 respectively to the channels 34 and 36 respectively, lead to a gate circuit 57, the output of which is connected to the input of the memory store 60. The signal outputs from the photodiodes 51 and 55, which are connected via the photoconductors 43 and 47 respectively to the channels 37 and 39 respectively, also lead to a gate circuit 58, which is connected to a further input of the store 60. The signal output of the photodiode 52, which is connected via the photoconductor 44 with the channel 35 and is used for reading the marks provided as code elements, is connected directly with the store 60, and the signal output of the photodiode 53, which is connected via the photoconductor 45 with the channel 38 and is used for reading the marks provided as synchronizing generators, is likewise directly connected to the store 60 and in addition to the input of a counter 61. The output of this counter is also connected to the store 60. From the output of the store, a line 62 leads to one input of a comparator 63.
The rotational device, not shown here, for the vessel 10 contains a switch 65, which is actuated when a vessel enters the rotating device. This switch is connected via a line 66 with the store 60.
In addition, one or more data input devices 68 are provided. Each data input device contains a sensing field, by means of which at least one number can be sensed. The output of each data input device is connected with the input of a multiplexer 69, the output of which is connected to the other input of the comparator 63.
FIG. 5 shows, in perspective, a light stop block 33. This block comprises six channels 34 to 39, which are disposed in two superimposed rows each of three channels 34, 35, 36 and 37, 38, 39. The cross-section of each channel is slightly larger than the cross-section of a mark, for example the mark 20' in FIG. 3. The light stop block is mounted in such a way that the longitudinal direction of the channels lies in the same direction as the light beam produced by the illuminating device 30, 31 and the middle dividing wall 40 between the two rows of channels is practically at the same height as the peripheral circle 17, as is shown for the light stop block indicated in broken lines in FIG. 2. The result of this arrangement is that light which penetrates below the peripheral circle through the vessel 10 falls upon one or more channels of the lower row (37, 38, 39), while light which passes through the vessel above the peripheral circle falls upon one or more channels of the upper row (34, 35, 36). With the form of embodiment shown, each of the channels also comprises a vertical dividing wall 70 to 75, which subdivides each channel into two narrow channels.
The illuminating device, reading device and electronic evaluating circuit are constructed of conventional components. It lies within the scope of any skilled person to find the most suitable components for a given specific purpose, so that no discussion will be given here on details of the electronic circuit and especially of the construction of the store 60 nor of the control of this store during input and retrieval.
For the following description of the use of the new apparatus, it will be assumed that a vessel 10 has entered a rotational device and is being rotated about its vertical axis 26. As already mentioned, when the vessel enters the rotational device, the switch 65 is actuated, which resets the store 60, that is deletes all stored signals. It will also be assumed that the vessel is rotated in the direction of arrow 80 and that the marking 11" is situated in the position shown in FIG. 4, that is not in the light path between the illuminating device 30, 31 and the reading device 32. The virtually parallel light beam produced by the illuminating device then passes through the vessel wall adjacent to the illuminating device into the vessel and through the vessel wall adjacent to the readin device out of the vessel, reading diffraction of the light beam upon entering the vessel being practically compensated by the diffraction as it immerges from the vessel again. Because the channels of the light stop block 33 are aligned to the direction of the light beam and the direction of the light is scarcely influenced by the vessel, the photoconductors disposed at the rear ends of the channels and thus the associated photodiodes are illuminated relatively uniformly. As already mentioned above, the illuminating of the photodiodes and the electrical signal emitted by these is dependent upon the color of the glass, thickness of vessel wall and optical quality of the vessel wall. It is possible for both the mean value of the illumination and also the temporary deviation from this mean value to undergo relatively large changes, as indicated in FIG. 6 diagrammatically for the periods T1, T3 and T5.
When the vessel 10 has rotated into a position in which a part of the emerging light passes through the marks of the marking, this part of the light is diffracted onto a convergence point or convergence region as a consequence of the lens effect of the marks. When a mark is situated in the light path in front of one of the channels of the light stop block 33, this diffraction has the effect that the light diverging again after the convergence point or region does not fall upon the photoconductor disposed at the rear end of the channel or upon the associated photodiode, but upon the walls of the channel, where it is absorbed. When a mark passes in front of a channel, the illuminating of the associated photodiode is therefore interrupted, and the output signal from the photodiode drops to zero, as indicated in FIG. 6 for the time intervals T2 and T4. In order that light which is only slightly diffracted shall not reach the rearward end of the channel, but instead shall be absorbed by a wall, the width of each channel, in one preferred embodiment of the light stop block, is again subdivided by a central partition 70 to 75. For the evaluation of the electrical signals generated by the photodiodes, it is then only necessary to set a threshold value detector to a predetermined value, for example to the value S indicated by a broken line in FIG. 6, and only to further process those signals which fall below this threshold value. In this way, the signals produced by the marks of the marking are not influenced by the unavoidable fluctuations in the illumination of the photodiodes which occur as light passes through the nonmarked vessel walls.
As already mentioned above, the pairs of marks 12, 19 and 15, 24 are provided for activating the reading device 32 and store 60. When the vessel is rotated in the direction indicated by arrow 80, the pair of marks 12 and 19 appear first in front of the channel 34, 37. In accordance with the above explanations, the output signals from the two photodiodes 50, 51 then fall below the threshold value, and the memory store 60 is activated. If the vessel is rotated contrary to arrow 80, then the pair of marks 15 and 24 appears first in front of the channels 36, 39, which causes the store 60 to be activated by the output signals from the two photodiodes 54, 55. The store then remains activated until, when the next vessel enters, the switch 65 is actuated and supplies a restoring signal. This means that all signals produced by the photodiodes 50, 51 or 54, 55 after activation of the store do not have any effect.
As the vessel rotates further, the marks 12, 19 are pushed into the light path in front of the channels 35, 38 respectively, so that the associated photodiode 53 produces a first synchronizing signal, which is conducted to the store 60 and to the counter 61. The store is so adjusted that the code signal associated with the first synchronizing signal is not stored. The counter 61 counts the fist synchronizing signal. When, with further rotation, the mark 20 appears in the light path before the channel 38, the photodiode 53 again produces a synchronizing signal, while the photodiode 52, subject to unchanged illumination, produces no signal. The synchronizing signal is counted in the counter 61 and has the effect in the memory store that the code element zero is stored in the storage cell associated with this second synchronizing signal. As the vessel revolves further, the two marks 13, 21 then appear in front of the channels 35, 38 respectively. The third synchronizing impulse produced by the mark 21 is again counted in the counter 61 and has the effect that the code element 1 produced by the mark 13 is stored in the storage cell associated with the third synchronizing signal.
With the marking system selected as example, when the marks 22 and 14, 23 pass before the channels 35 and 38 of the light stop block, the same operations are initiated as described above for the marks 20 and 13, 21. Because the marking system selected as example contains four code elements, the counter 61 is so adjusted that after the fifth synchronizing signal (the first synchronizing signal from the "start" mark 19 and the four synchronizing impulses produced by the synchronizing marks 20 to 23) it blocks the store input and at the same time conducts the contents of the memory store via the conductor 62 to the one input of the comparator 63.
It will be understood that when markings comprising several tetrads of code elements are used, the counter can be adjusted accordingly.
When vessels having a specific ordinal number are to be sorted out, then this ordinal number is input into the input device 68. The device converts the input ordinal number into the same code as is used for marking the vessels, so that the comparator 63 can compare the two codings. In an embodiment tested in practice, a multiplexer 69 is connected between the input device 68 and comparator 63. This arrangement enables a number of ordinal numbers to be input into the input device and to be stored there, and the ordinal number read off from the vessel to be compared with the several ordinal numbers input into the input device. If the ordinal number read off from the vessel agrees with the ordinal number or one of the ordinal numbers input into the input device, then a signal appears at the output 82 of the comparator. This signal can be used in known manner for rejecting the corresponding vessel out of the sorting line.
In one arrangement, already tested in practice, of the new method of identifying the mold in which a glass vessel has been molded, the marking shown in FIG. 7 is used. This marking comprises two tetrads 85 and 86 for coding the mold number, and the marks 87 and 88 used for generating the start signal are formed identically to the eight timing marks 89. With this marking system also, the eight timing marks 89 are disposed below the circular path 84 and between the two marks 87, 88, provided for triggering the start signal. The code elements of the two tetrads 85 and 86 disposed above the circular path are constituted as vertical extensions of the timing marks 89. As in the marking system already described, each code element shaped as a cylindrical lens corresponds to a binary "1" and the undeformed vessel wall to a binary "0". The vessel number shown as an example in FIG. 7 by the two tetrads 85 and 86, corresponds, when reading from the mark 87 towards the mark 88, to the number 35 in BCD code. Each of the marks used for generating the start signal and each of the timing marks is constructed as a cylindrical lens and projects about 0.35 mm from the vessel wall. These marks have a height of about 3.5 mm. The width of the marks and the spacing between two adjacent marks are about 1.1 mm. The marks of the code elements possess the same cross-section as the timing marks, but their height is only about 2.5 mm.
The light stop block used for reading the marking described is shown in FIG. 8. This light stop block is shown considerably enlarged by comparison with the marking illustrated in FIG. 7, for clarity of understanding. The light stop block 91 comprises five light stop channels 92 to 96. Channel 92 is provided for the timing marks and channel 93 for the code elements. Because the marks 87, 88 provided for triggering the start signal are not higher than the timing marks, the light stop block possesses, for these marks also, only one channel 94, 95 respectively disposed at the level of channel 92. The fifth channel 96 is disposed at such a height that the light falling upon it is not influenced by the marking. The use of this fifth channel will be described below. The cross-section of the channels is substantially smaller than the cross-section of the individual marks measured in the direction of the incident light. The aim of this is to ensure that the light stop formed by the channel lies as far as possible always in the vicinity of the optical axis of the cylindrical lens formed by the marks. In this way, the diffraction of the light aimed at by the use of the cylindrical lenses is also effectively used when individual cylindrical lenses are displaced relative to their theoretically determined position or possess an inadequate or defective form. A light stop block which can be used for the marks described in the foregoing section possesses, for example, channels having a width of about 0.25 mm, a height of about 1 mm and a length of about 10 mm. These channels are preferably formed as sawtooth slits, the upper and lower open sides of which are covered with thin plates 97, 98 and 99.
FIG. 9 shows diagrammatically a lateral view of a vessel 100 in the reading position, the illuminating device 101 and the light stop block 91 with associated photodiodes. As already described earlier, the marking is disposed in the region of the bottom turned-in part of the vessel, so that the marks do not get damaged when vessels strike one another. In order that the marks used as optical lenses shall as far as possible be perpendicular to the axis 102 of the light beam, the illuminating device 101 is appropriately inclined. The light stop block 91 has the same inclination, in order that the individual channels shall extend in the direction of the non-diffracted light. On the side of the light stock block remote from the vessel, a support plate 105 is disposed. The distance between light stop block and support plate is about 2 mm. On the support plate small collector lenses are mounted in the direct extensions of the channels of the light stop block; of these, only the lenses 106, 107 and 108 can be seen in FIG. 9, these being associated with the channels 96, 93 and 94. These lenses collect the light arriving through the corresponding channel and conduct it to an associated photodiode 110, 111 and 112 respectively. With this arrangement of the photodiodes in the direct vicinity of the channels of the light stop block, the use of additional photoconductors between channel and photodiode (as described for the embodiment of FIG. 4) is not necessary.
The evaluation circuit connected after the photodiodes corresponds to th circuit the in FIG. 4, with the difference that the gate circuits 57, 58 are not required.
The method of operation of the photodiodes associated with channels 92, 93, 94 and 95 is the same as that for the photodiodes 53, 52, 51 and 55 respectively, as already explained with the help of FIG. 4, so that further description will not be given here.
As already mentioned above, the channel 96 and the photodiode 110 associated with it are so arranged that the light falling upon them is not influenced by the marking. The photodiode 110 is used as an actual value emitter (reading emitter) in a control circuit not shown here, which regulates the voltage to the light source in the illuminating device. The result of this arrangement is that the density of illumination upon the photodiodes remains virtually constant independently of changes in the thickness or color of the vessel wall or of the aging of the light source over long periods of time. Suitable control circuits for this purpose are known to any skilled person, so that a description of same will not be given here.
As practical testing has demonstrated, it is possible for the marking described to be read with the reliability required for industrial purposes from a glass vessel of 60 mm diameter even at the circumferential speed of 3.5 m/sec. which is usual in the stations of a sorting line.
It will be understood that the light stop block and support plate for the photodiodes are incorporated in a light proof housing. In order to prevent excessive heating of the photodiodes and accumulation of dirt in the light stop channels, cool pressurized air can be introduced into the housing, flowing out through the channels. It will also be understood that the illuminating device and the light stop block together with the photodiodes are preferably mounted adjustable in height and pivotal, in order that the device can be utilized for vessels of differing dimensions.
The reliability of reading of the code elements and timing marks of a marking may be adversely affected by the properties of the vessel wall. For instance, steeply domed bottoms of bottles cause deflection of the entire light beam. This total deflection can be greater than the partial deflection caused by the markings, in which case the markings do not produce in the reading device a difference in illumination which can be evaluated. Furthermore, the capability for evaluation of the differences in illumination produced by the marking on the photodiodes of the reading device is dependent upon the transparency of the vessel wall. When light shines through the lateral walls of a vessel, the reliability of reading decreases when the light beam is displaced from the maximum vessel diameter towards the vessel edge. It will also be understood that faults in the vessel wall, for example bubbles or cords, can produce fault signals in the reading device which cannot be distinguished from the signals caused by markings.
The above discussed sources of errors may be avoided by illuminating and reading of the marking in incident light. Reading in incident light enables markings to be read with high reliability, uninfluenced by the transparency of the material of the vessel, by the curvature of the vessel wall carrying the markings and by possible faults in the glass. With this method, it is also not necessary for the light beam which is used for illuminating the vessel wall carrying the markings to be directed towards the axis of the vessel. The improved device can be constructed as simply as the device previously described, but has the advantage that it requires less room than the previous device and can therefore be added on more simply to already existing testing equipment.
The device shown diagrammatically in plan in FIG. 10 contains a rotating device not shown for rotating a vessel 10' about its axis of symmetry 26'. Furthermore, an illuminating device 29 is provided, comprising a light source 30' and condenser lens 31'. In this form of embodiment, the illuminating device is so disposed that the emerging light beam is in a plane situated transversely to the axis 26' of rotation and symmetry of the vessel 10'. The illuminating device can be pivoted in this plane and displaced in the direction of the light beam in order to illuminate on the peripheral circle of the vessel on which the marking 11' is disposed a region having a diameter somewhat larger than the height of the two-part marking, in the example described about 12 mm (for a height of about 7 mm for the two-part marking shown in FIG. 3). The illuminating device is also adjustable in height in order to illuminate markings disposed at different levels on the vessel wall. The device further contains a light shielding block 33' into which light conductors are introduced as shown in FIG. 4. Instead of the light conductors photodiodes may be inserted in the light shielding block. In front of the light shielding block 33' a projection optic 41 is disposed, which images the region of the vessel wall illuminated by the light source onto the inlet ends of the light conductors or directly onto the appropriate photodiodes. The optical axes of the projection optic and of the light shielding block lie in the same plane as the illuminating device. The angle α between the optical axes is, in a preferred embodiment, about 70°, as will be described in more detail below.
As any skilled person will readily understand, it is possible without difficulty to arrange the illuminating device and projection optic and also the light shielding block in such a manner that a marking at the mouth of the vessel can be illuminated and imaged in the light shielding block. With an embodiment of this type, the optical axes of the illuminating device and projection optic lie practically on a conical surface.
It is, of course, also possible so to arrange the illuminating device and the projection optic together with the light shielding block that a marking disposed upon the bottom of the vessel is illuminated and imaged in the light shielding block. If the bottom of the vessel is flat, the corresponding optical axes then lie practically on a cylindrical surface.
FIG. 11 shows a highly enlarged, horizontal section through a part of a vessel wall and three code elements or timing marks 120, 121, 122 projecting from this wall. As can be clearly seen in this figure, the code elements or timing marks possess a circular arc shaped cross-section which is, however, definitely smaller than a semi-circle. (Practical experience has shown that code elements and timing marks with this flattened type of cross-section are more simple to mold than semi-circular or semi-spherical elements.) The light from the illuminating device falling obliquely onto the vessel wall, the direction of which is, for example, along line 123, is according to known laws to a major portion refracted into the vessel wall (line 123') and to a minor portion reflected in the direction of line 124, without reaching the reading device. The light incident in the same direction, corresponding for example to line 126 and striking one side of code element 121, is also to a major portion refracted in the vessel wall (line 126') and to a minor portion reflected. Depending upon the direction of the tangent line of the reflecting area of the code element this reflected light has the direction for instance of line 127. A chord 128 can be associated with the curvature of the part of the code element towards the incident light, which chord connects together the transition between the vessel wall and code element and the furthest projecting point of the code element. In the example shown, this chord is at an angle β of about 35° to the tangent 129 to the vessel wall in the region of the code element 121. Although the incident light is reflected and possibly diffusely reflected or scattered in a plurality of directions on the convex surface of the code element, this reflecting surface may be replaced, to a coarse approximation, by the chord 128 and if, as shown in FIG. 10, the optical axis of the projection optic and of the light shielding block intersects the vessel axis, that is to say it is perpendicular to the tangent 129, then it is to be expected that an optimum quantity of light will be reflected into the reading device if the angle α between the optical axes of the illuminating and reading devices is virtually 70°. Practical experience hitherto has confirmed this argument. The markings can be read with the necessary reliability if the angle between said optical axes lies in the range between 60° and 80°.
As shown in FIG. 11 each illuminated code element does not only act as a reflector but produces a shadow region 130 in the immediate vicinity of the reflecting area. The sharp transition from the reflecting area to the shadow region improves the edge steepness of the read signal and therefore the reliability of the signal detection.
FIG. 12 shows diagrammatically the illumination of the input surface of a light conductor or a photodiode of the reading device as a vessel is rotated in the direction indicated by arrow 131. During period T a the vessel wall between code elements 120 and 121 is illuminated. As already described above, the light reflected from the vessel wall does not reach the reading device. On account of the light shielding block 33', which almost completely excludes all unintentional diffusely reflected and scattered light, the illumination of the photodiodes during this period is practically zero. During the subsequent period of time T b the side of the code element 121 facing toward the incident light is illuminated and light is reflected into the reading device. Because the reflecting surface of the code element does not correspond to the above assumed chord 128 but is a circular arc, the direction of the reflected light lies for only a very short period in the optimum direction along line 127. A brief consideration will show that the illumination of the photodiode with reflected light at first increases slowly and then very rapidly, reaches a maximum value and again falls rapidly off before period T b has ended. Then, during the passage of the unilluminated side of code element 121 and the vessel wall between the two code elements 121 and 122 there follows a period T c , during which the photodiode is not illuminated. When code element 122 enters the region of the light beam from the illuminating device the same process is repeated during a period T d , as that already described for period T b .
When a marking is read in transmitted (through) light according to FIGS. 4 and 6 the reading device which is illuminated at the at-rest state becomes darkened. When reading a marking in incident light the reading device which is unilluminated in the at-rest state becomes illuminated. As any skilled person will readily understand, the corresponding output signals of the reading device can be reversed by simple electronic means, so that the electronic evaluation of the signals described with reference to FIG. 4 can also be used when reading with incident light.
In accordance with the above considerations and the discussion of the illuminating of the photodiodes with reference to FIG. 12 it will also be understood that a practically rectangular reading signal having a large signal amplitude is obtained if instead of the described code elements having a circular arc cross-section code elements having a practically triangular cross-section are used.
Although in the embodiment as described in connection with FIG. 10 the optical axis of the reading device intersects the axis of rotation of the rotating device, it will be understood that the reading with incident light is also possible if the optical axis of the reading device is laterally offset with respect to the axis of rotation of the rotating device (and of the vessel).
It further will be understood that the described new process may be used with the same advantage if the marked vessels are not rotated but simply advanced in a rectilinear or bent conveyor path in front of the reading device, while the marking is directed towards this reading device. This embodiment of the new method is specially suitable for reading the marking on vessels with rectangular cross-section. | The identification of a mold in which a vessel made from an optically transparent material has been molded. The vessel is provided with a plurality of marks disposed about a path on the wall of the vessel. There is a first set of marks disposed above the path and a second set disposed below the path. One of the first or second sets contains code marks for providing an indication of the mold and the other set contains timing marks suitable for the sequential reading of the code marks. The marks are illuminated by a light path as the vessel is moved and the diffraction or reflection of the light caused by the marks is evaluated. Time impulses are generated in response to the evaluation of the timing marks for sequential reading of the code marks. | 1 |
This is a continuation in part of U.S. Ser. No. 09/606,324 filed Jun. 28, 2000, now U.S Pat. No. 6,437,215 which claims priority to U.S. Ser. No. 60/141,361 filed Jun. 28, 1999 and U.S. Ser. No. 60/164,679 filed Nov. 10, 1999.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
The U.S. government has certain rights to this invention by virtue of Grants HL41484, HI-52212, and HL20948 from the National Institutes of Health-National Heart, Lung and Blood Institute to Monty Kreiger and HL63609 and HL53793 to M. Simons and M. J. P. from the US National Institutes of Health.
BACKGROUND OF THE INVENTION
The present invention is generally in the area of transgenic animal models of atherosclerosis, methods for screening for inhibitors acting via interaction with the SR-BI scavenger receptor, and compositions obtained thereby.
The intercellular transport of lipids through the circulatory system requires the packaging of these hydrophobic molecules into water-soluble carriers, called lipoproteins, and the regulated targeting of these lipoproteins to appropriate tissues by receptor-mediated pathways. The most well characterized lipoprotein receptor is the LDL receptor, which binds to apolipoproteins B-100 (apoB-100) and E (apoE), which are constituents of low density lipoprotein (LDL), the principal cholesteryl-ester transporter in human plasma, very low-density lipoprotein (VLDL), a triglyceride-rich carrier synthesized by the liver, intermediate-density lipoprotein (IDL), and catabolized chylomicrons (dietary triglyceride-rich carriers).
All members of the LDL receptor gene family consist of the same basic structural motifs. Ligand-binding (complement-type) cysteine-rich repeats of approximately 40 amino acids are arranged in clusters (ligand-binding domains) that contain between two and eleven repeats. Ligand-binding domains are always followed by EGF-precursor homologous domains. In these domains, two EGF-like repeats are separated from a third EGF-repeat by a spacer region containing the YWTD motif. In LRP and gp330, EGF-precursor homologous domains are either followed by another ligand-binding domain or by a spacer region. The EGF-precursor homology domain, which precedes the plasma membrane, is separated from the single membrane-spanning segment either by an O-linked sugar domain (in the LDL receptor and VLDL receptor) or by one (in C. elegans and gp330) or six EGF-repeats (in LRP). The cytoplasmic tails contain between one and three “NPXY” internalization signals required for clustering of the receptors in coated pits. In a later compartment of the secretory pathway, LRP is cleaved within the eighth EGF-precursor homology domain. The two subunits LRP-515 and LRP-85 (indicated by the brackets) remain tightly and non-covalently associated. Only partial amino acid sequence of the vitellogenin receptor and of gp330 are available.
LDL receptors and most other mammalian cell-surface receptors that mediate binding and, in some cases, the endocytosis, adhesion, or signaling exhibit two common ligand-binding characteristics: high affinity and narrow specificity. However, two additional lipoprotein receptors have been identified which are characterized by high affinity and broad specificity: the macrophage scavenger receptors class A type I and type II.
Scavenger receptors mediate the binding of chemically modified lipoproteins, such as acetylated LDL (AcLDL) and oxidized LDL (OxLDL), and have been implicated in the pathogenesis of atherosclerosis (Krieger and Herz, 1994 Annu. Rev. Biochem. 63, 601-637; Brown and Goldstein, 1983 Annu. Rev. Biochem. 52, 223-261; Steinberg et al., 1989 N. Engl. J. Med. 320, 915-924). Macrophage scavenger receptors exhibit complex binding properties, including inhibition by a wide variety of polyanions, such as maleylated BSA (M-BSA) and certain polynucleotides and polysaccharides, as well as unusual ligand-cross competition (Freeman et al., 1991 Proc. Natl. Acad. Sci. U.S.A. 88, 4931-4935, Krieger and Herz, 1994). Several investigators have suggested that there may be at least three different classes of such receptors expressed on mammalian macrophages, including receptors which recognize either AcLDL or OxLDL, or both of these ligands (Sparrow et al., 1989 J. Biol. Chem. 264, 2599-2604; Arai et al., 1989 Biochem. Biophys. Res. Commun. 159, 1375-1382; Nagelkerke et al., 1983 J. Biol. Chem. 258, 12221-12227). The first macrophage scavenger receptors to be purified and cloned were the mammalian class A type I and II receptors. These are trimeric integral membrane glycoproteins whose extracellular domains have been predicted to include α-helical coiled-coil, collagenous and globular structures (Kodama et al., 1990 Nature 343, 531-535; Rohrer et al., 1990 Nature 343, 570-572; Krieger and Herz, 1994). The collagenous domain, shared by the class A type I and type II receptors, apparently mediates the binding of polyanionic ligands (Acton et al., 1993 J. Biol. Chem. 268, 3530-3537; Doi et al., 1993 J. Biol. Chem. 268, 2126-2133). The class A type I and type II molecules, which are the products of alternative splicing of a single gene, are hereafter designated class A scavenger receptors (SR-AI and SR-AII). The class A receptors, which bind both AcLDL and OxLDL (Freeman et al., 1991), have been proposed to be involved in host defense and cell adhesion, as well as atherogenesis (Freeman et al., 1991; Krieger, 1992 Trends Biochem. Sci. 17, 141-146; Fraser et al., 1993 Nature 364, 343-346; Krieger and Herz, 1994).
Based on models of the predicted quaternary structures of the class A type I and type II macrophage scavenger receptors, both contain six domains, of which the first five are identical: the N-terminal cytoplasmic region, the transmembrane region, spacer, α-helical coil, and collagen-like domains. The C-terminal sixth domain of the type I receptor is composed of an eight-residue spacer followed by a 102-amino acid cysteine-rich domain (SRCR), while the sixth domain of the type II receptor is only a short oligopeptide.
Using a murine macrophage cDNA library and a COS cell expression cloning technique, Endemann, Stanton and colleagues, (Endemann, et al. 1993 J. Biol. Chem. 268, 11811-11816; Stanton, et al. J. Biol. Chem. 267, 22446-22451), reported the cloning of cDNAs encoding two additional proteins that can bind OxLDL. The binding of OxLDL to these proteins was not inhibited by AcLDL. These proteins are FcgRII-B2 (an Fc receptor) (Stanton et al., 1992) and CD36 (Endemann et al., 1993). The significance of the binding of OxLDL to FcgRII-B2 in transfected COS cells is unclear because FcgRII-B2 in macrophages apparently does not contribute significantly to OxLDL binding (Stanton et al., 1992). However, CD36 may play a quantitatively significant role in OxLDL binding by macrophages (Endemann et al., 1993). In addition to binding oxidized LDL, CD36 binds thrombospondin (Asch et al., 1987 J. Clin. Invest. 79, 1054-1061), collagen (Tandon et al., 1989 J. Biol. Chem. 264, 7576-7583), long-chain fatty acids (Abumrad et al., 1993 J. Biol. Chem. 268, 17665-17668) and Plasmodium falciparum infected erythrocytes (Oquendo et al., 1989 Cell 58, 95-101). CD36 is expressed in a variety of tissues, including adipose, and in macrophages, epithelial cells, monocytes, endothelial cells, platelets, and a wide variety of cultured lines (Abumrad et al., 1993; and see Greenwalt et al., 1992 Blood 80, 1105-1115 for review). Although the physiologic functions of CD36 are not known, it may serve as an adhesion molecule due to its collagen-binding properties. It is also been proposed to be a long-chain fatty acid transporter (Abumrad et al., 1993) and a signal transduction molecule (Ockenhouse et al., 1989 J. Clin. Invest. 84, 468-475; Huang et al., 1991 Proc. Natl. Acad. Sci. USA 88, 7844-7848), and may serve as a receptor on macrophages for senescent neutrophils (Savill et al., 1991 Chest 99, 7 (suppl)).
Modified lipoprotein scavenger receptor activity has also been observed in endothelial cells (Arai et al., 1989; Nagelkerke et al., 1983; Brown and Goldstein, 1983; Goldstein et al., 1979 Proc. Natl. Acad. Sci. U.S.A. 76, 333-337). At least some of the endothelial cell activity apparently is not mediated by the class A scavenger receptors (Bickel et al., 1992 J. Clin. Invest. 90, 1450-1457; Arai et al., 1989; Nagelkerke et al., 1983; Via et al., 1992 The Faseb J. 6, A371), which are often expressed by macrophages (Naito et al., 1991 Am. J. Pathol. 139, 1411-1423; Krieger and Herz, 1994). In vivo and in vitro studies suggest that there may be scavenger receptor genes expressed in endothelial cells and macrophages which differ from both the class A scavenger receptors and CD36 (Haberland et al., 1986 J. Clin. Inves. 77, 681-689; Via et al., 1992; Sparrow et al., 1989; Horiuchi et al., 1985 J. Biol. Chem. 259, 53-56; Arai et al., 1989; and see below). Via, Dressel and colleagues (Ottnad et al., 1992 Biochem J. 281, 745-751) and Schnitzer et al. 1992 J. Biol. Chem. 267, 24544-24553) have detected scavenger receptor-like binding by relatively small membrane associated proteins of 15-86 kD. In addition, the LDL receptor related protein (LRP) has been shown to bind lipoprotein remnant particles and a wide variety of other macromolecules. Both the mRNA encoding LRP and the LRP protein are found in many tissues and cell types (Herz, et al., 1988 EMBO J. 7:4119-4127; Moestrup, et al., 1992 Cell Tissue Res. 269:375-382), primarily the liver, the brain and the placenta. The predicted protein sequence of the LRP consists of a series of distinctive domains or structural motifs, which are also found in the LDL receptor.
As described by Kreiger, et al., in PCT/US95/07721 “Class BI and CI Scavenger Receptors ” Massachusetts Institute of Technology (“Krieger, et al.”), two distinct scavenger receptor type proteins having high affinity for modified lipoproteins and other ligands have been isolated, characterized and cloned. Hamster and murine homologs of SR-BI, an AcLDL and LDL binding scavenger receptor, which is distinct from the class A type I and type II macrophage scavenger receptors, has been isolated and characterized. In addition, DNA encoding the receptor cloned from a variant of Chinese Hamster Ovary Cells, designated Var-261, has been isolated and cloned. dSR-CI, a non-mammalian AcLDL binding scavenger receptor having high ligand affinity and broad specificity, was isolated from Drosophila melanogaster.
It was reported by Kreiger, et al. that the SR-BI receptor is expressed principally in steroidogenic tissues and liver and appears to mediate HDL-transfer and uptake of cholesterol. Competitive binding studies show that SR-BI binds LDL, modified LDL, negatively charged phospholipid, and HDL. Direct binding studies show that SR-BI expressed in mammalian cells (for example, a varient of CHO cells) binds HDL, without cellular degradation of the HDL-apoprotein, and lipid is accumulated within cells expressing the receptor. These studies indicate that SR-BI might play a major role in transfer of cholesterol from peripheral tissues, via HDL, into the liver and steroidogenic tissues, and that increased or decreased expression in the liver or other tissues may be useful in regulating uptake of cholesterol by cells expressing SR-BI, thereby decreasing levels in foam cells and deposition at sites involved in atherogenesis.
Atherosclerosis is the leading cause of death in western industrialized countries. The risk of developing atherosclerosis is directly related to plasma levels of LDL cholesterol and inversely related to HDL cholesterol levels. Over 20 years ago, the pivotal role of the LDL receptor in LDL metabolism was elucidated by Goldstein, et al., in the Metabolic and Molecular Bases of Inherited Disease, Scriver, et al. (McGraw-Hill, NY 1995), pp. 1981-2030. In contrast, the cellular mechanisms responsible for HDL metabolism are still not well defined. It is generally accepted that HDL is involved in the transport of cholesterol from extrahepatic tissues to the liver, a process known as reverse cholesterol transport, as described by Pieters, et al., Biochim. Biophys. Acta 1225, 125 (1994), and mediates the transport of cholesteryl ester to steroidogenic tissues for hormone synthesis, as described by Andersen and Dietschy, J Biol. Chem. 256, 7362 (1981). The mechanism by which HDL cholesterol is delivered to target cells differs from that of LDL. The receptor-mediated metabolism of LDL has been thoroughly described and involves cellular uptake and degradation of the entire particle. In contrast, the receptor-mediated HDL metabolism has not been understood as well. Unlike LDL, the protein components of HDL are not degraded in the process of transporting cholesterol to cells. Despite numerous attempts by many investigators, the cell-surface protein(s) that participate in the delivery of cholesterol from HDL to cells had not been identified before the discovery that SR-BI was an HDL receptor.
It is an object of the present invention to provide methods and reagents for designing drugs that can stimulate or inhibit the binding to and lipid movements mediated by SR-BI and redirect uptake and metabolism of lipids and cholesterol by cells.
It is another object of the present invention to provide methods and compounds for the treatment of atherosclerosis.
SUMMARY OF THE INVENTION
Transgenic animals that do not express functional SR-BI and ApoE develop severe atherosclerosis, by age four weeks in transgenic mice. Moreover, these animals exhibit progressive heart dysfunction starting by age four-six weeks, and die by age nine weeks. Pathology shows extensive fibrosis of the heart and occlusion of coronary arteries. The occlusion appears to be due to atherosclerosis, since fat deposition is in the walls. These animals are good models for the following diseases, and for screening of drugs useful in the treatment and/or prevention of these disorders: cardiac fibrosis, myocardial infarction, defects in electrical conductance, atherosclerosis, unstable plaque, and stroke. In contrast to other known models for atherosclerosis, these animals do not have to be fed extreme diets for long periods before developing atherosclerosis and heart dysfunction. No other known model for heart attacks and stroke with these characteristics is known.
This animal model has now been demonstrated to be useful as a screen for compounds which alleviate the symptoms of atherosclerosis and heart disease. Animals (Apo E−/−SR-BI+/−) were fed PROBUCOL beginning at the time of mating. Offspring are weaned at three weeks and fed PROBUCOL. In contrast to animals not fed PROBUCOL, 50% of whom are dead at six weeks, all animals on PROBUCOL have a normal phenotype (MRI of heart function, ECG, echocardiogram, histology) at six weeks. At seven to eight months, there is evidence of atherosclerosis and some myocardial infarction. This demonstrates that the compound has a preventative action. Animals who are taken off of the PROBUCOL all die within ten to twelve weeks. In another study, the majority of animals whose parents were not fed PROBUCOL, but who received the PROBUCOL beginning before five weeks of age, survived for a few months, demonstrating that the compound also has a therapeutic benefit. The earlier the treatment with PROBUCOL, the longer the survival of the animals.
DETAILED DESCRIPTION OF THE INVENTION
The role of SR-BI has now been confirmed as the principle mediator of cholesteryl ester transport from peripheral tissues to the liver and other steroidogenic tissues, including the adrenal gland, testes and ovaries. The studies described herein demonstrate that animals which are deficient in both SR-BI and ApoE are not only excellent models for atheroslerosis but also myocardial infarction and stroke, since the animals develop progressive heart dysfunction and coronary artery occlusions characterized by plaques resembling those in heart attack patients.
These animals can be used to screen for drugs that are effective as therapeutics or diagnostics of heart disease as demonstrated in the examples. As also demonstrated by the examples, compounds have been identified as useful in treating or preventing atherosclerosis or heart attack in individuals having deficiencies in SR-BI.
Pharmaceutical Compounds
A number of compounds are useful in altering lipid levels and cholesterol metabolism. A preferred class of compounds are PROBUCOL (4,4′-(isopropylidenedithio) bis(2,6-di-tert-butylphenol)) and monoesters of PROBUCOL, for example, as described in U.S. Pat. No. 6,121,319 to Somers and other derivatives as described by FR 2168137, FR 2140771, FR 2140769, FR 2134810, FR 2133024, and FR 2130975. These compounds have potent antioxidant properties and block oxidative modification of LDL. PROBUCOL has two known effects: (1) hypocholesterolemic agent (reduces plasma cholesterol, HDL and LDL in humans—side effect, causes long QT syndrome, which their esters avoid, as well as decrease in HDL) and (2) an antioxident, may also play a role in fertility.
Another useful compound available from Chugai of Japan is BO 653, 2,3-Dihydro-5-hydroxy-2,2-dipentyl-4,6-di-tert-butyl-benzofuran, an antioxident. Noguchi, et al., Arch. Biochem. Biophys. 1:347 (1997).
Based on the PROBUCOL data, other compounds that will be effective include other hypocholesterolemic and antioxident compounds, including vitamin E and vitamin C, as fertility enhancing agents as well as for treatment and/or prevention of cardiovascular disease or atherosclerosis. The preferred compounds would have both activities.
Pharmaceutical Compositions
Compounds are preferably administered in a pharmaceutically acceptable vehicle. Suitable pharmaceutical vehicles are known to those skilled in the art. For parenteral administration, the compound will usually be dissolved or suspended in sterile water or saline. For enteral administration, the-compound will be incorporated into an inert carrier in tablet, liquid, or capsular form. Suitable carriers may be starches or sugars and include lubricants, flavorings, binders, and other materials of the same nature.
Alternatively, the compound may be administered in liposomes or microspheres (or microparticles). Methods for preparing liposomes and microspheres for administration to a patient are known to those skilled in the art. U.S. Pat. No. 4,789,734 describe methods for encapsulating biological materials in liposomes. Essentially, the material is dissolved in an aqueous solution, the appropriate phospholipids and lipids added, along with surfactants if required, and the material dialyzed or sonicated, as necessary. A review of known methods is by G. Gregoriadis, Chapter 14. “Liposomes”, Drug Carriers in Biology and Medicine pp. 287-341 (Academic Press, 1979). Microspheres formed of polymers or proteins are well known to those skilled in the art, and can be tailored for passage through the gastrointestinal tract directly into the bloodstream. Alternatively, the compound can be incorporated and the microspheres, or composite of microspheres, implanted for slow release over a period of time, ranging from days to months. See, for example, U.S. Pat. Nos. 4,906,474, 4,925,673, and 3,625,214.
The pharmaceutical compositions are administered in an effective amount effective to modify or treat the disorder. These are readily determined by measuring blood, urine and/or tissue samples using clinically available tests, as demonstrated below.
The present invention will be further understood by reference to the following non-limiting examples.
EXAMPLE 1
Production and Characterization of Transgenic Animals that do not Express SR-BI
To determine directly if SR-BI normally plays an important role in HDL metabolism in vivo and to establish an experimental system to examine the role of SR-BI in pathologic states, mice containing a targeted null mutation in the gene encoding SR-BI were generated.
Materials and Methods
Generation of SR-BI Mutant Mice
SR-BI genomic DNA was isolated from a mouse strain 129 DNA library (Genome Systems, St. Louis, Mo.), and screened by PCR amplification using primer pairs corresponding to the 5′ and 3′ ends of the mSR-BI cDNA. From one clone a 12 kb Xba I fragment containing the first coding exon was identified. A replacement-type targeting vector, containing 0.75 kb and 9 kb short and long homology regions and the po12sneobpA and herpes simplex virus thymidine kinase (TK) cassettes, was constructed using standard methods. The vector was linearized and 100 μg were transfected by electroporation (240 V, 500 μF) into 112×10 6 murine D3 embryonic stem cells, which were then plated onto irradiated mouse embryonic fibroblast feeder layers. After G418/gancyclovir positive/negative selection for 7-8 days, 492 of the 5800 surviving colonies were picked and screened by PCR analysis using primers specific for the targeted allele (primer 15′-TGAAGGTGGTCTTCAAGAGCAGTCCT-3′ (SEQ ID NO:1); and primer 3 5′-GATTGGGAAGACAATAGCAGGCATGC-3′ (SEQ ID NO:2); all oligonucleotide primers were synthesized by Research Genetics). The presence of the targeted allele (amplification of a 1.4 kb band) was confirmed by Southern blot analysis of Xba I digested genomic DNA using probes that yielded either the predicted 12 kb fragment characteristic of the wild-type allele or the predicted 2.5 kb and 9 kb fragments from the targeted mutant allele. Bam HI digested genomic DNA was also probed with a 0.9 kb fragment derived by Pst I digestion of the neomycin resistance gene cassette to confirm the presence of a single neo gene in the mutant cells. Embryonic stem cell clones containing a disrupted SR-BI allele were injected into C57BL/6 blastocysts, which were implanted into recipient females. The resulting chimeric mice were crossed to C57BL/6 female mice to generate F1 wild-type (srbI +/+ ) and heterozygous (srbI+/ +− ) mice on an identical 129 (agouti)/C57BL/6 background. F1 heterozygotes were crossed to generate F2 wild-type (srbI +/+ ), heterozygous mutant (srbI +/− ) and homozygous mutant (srbI +/− ) progeny. The presence of the targeted or wild-type SR-BI alleles in DNA extracted from tail biopsies was detected by PCR amplification using primer 1 (SEQ ID NO: 1) in combination with either primer 3 (SEQ ID NO:2) (mutant specific) or primer 2 (wild-type specific; 5′-TATCCTCGGCAGACCTGAGTCGTGT-3′ (SEQ ID NO:3)). Genotypes were confirmed by Southern blot analysis. Mice were housed in microisolator cages and were fed ad libitum a regular rodent chow diet (Prolab 3000, PMI Feeds Inc., St. Louis, Mo.).
Analysis of Animal Tissues
Samples were obtained from fasted (4-8 hrs) or non-fasted mice that were approximately 8-12 weeks old (F1 generation) or 5-11 weeks old (F2 generation).
Immunoblot Analysis
Animals were sacrificed and livers and adrenal glands were removed and immediately frozen. Membranes from homogenates were prepared. 50 μg of protein per specimen were analyzed by SDS-polyacrylamide (8%) gel electrophoresis and immunoblotting with chemiluminescence detection as previously described using rabbit antipeptide polyclonal antibodies which specifically recognize either the approximately 82 kDa murine SR-BI protein (anti-mSR-BI 485 ) or the approximately 36 kDa ε-COP control cytoplasmic protein (anti-εCOP).
Plasma and Adrenal Cholesterol Analysis
Plasma total cholesterol (unesterified plus esterified, mg/dl) was measured using an enzymatic kit (Sigma Chemicals, St. Louis, Mo.). Adrenal glands were homogenized as described above. Protein concentrations in the homogenates were measured using the method of Lowry et al. Duplicate samples of homogenates (30-70 μl each) were extracted with 2 ml of hexane/isopropanol (2:1) for 1 h at room temperature, back-washed with 1 ml of water, and phases separated by centrifugation at 800× g for 5 min. The upper organic phase was recovered and evaporated at 37° C. in a Speedvac concentrator and cholesterol was measured in the dried pellet using an enzymatic kit (Sigma). Cholesterol values were corrected based on the recovery of a [ 3 H]cholesteryl ester internal standard added prior to lipid extraction. Total cholesterol content was expressed as μg of cholesterol/mg total protein.
Lipoprotein Analysis
Pooled plasma (150 μl total from 2-6 animals) was diluted with an equal volume of elution buffer (154 mM NaCl 1 mM EDTA, pH 8) and subjected to FPLC using two Superose 6 columns (Pharmacia, Piscataway, N.J.) connected in series. Proteins were eluted at 0.25 ml/min. Forty seven fractions (0.5 ml) were collected after the first 14 ml were eluted and total cholesterol in each fraction was determined as described above. Immunoblotting of the FPLC fractions was performed with specific anti-apoA-I, anti-apoA-II or anti-apoE antibodies on independent samples or by sequential labeling of a single membrane to permit simultaneous visualization of all three proteins.
Statistical Analysis
Results are expressed as the arithmetic mean ± standard deviation. The statistical significance of the differences of the mean between groups was evaluated using the Student t test for unpaired comparisons. The χ 2 test was used for genotype distribution analysis. P values <0.05 are considered to be statistically significant.
Results and Discussion
The SR-BI gene was inactivated in embryonic stem cells by standard homologous recombination methods. The segments replaced in the recombined mutant (“Targeted Allele”) include the entire coding region of the first coding exon (126 bp, 42 amino acids, containing 5′ untranslated sequence, a short N-terminal cytoplasmic domain, and a portion of the N-terminal putative transmembrance domain that probably also functions as an uncleaved leader sequence for insertion into the ER during biogenesis) and an additional 554 bases of the adjacent downstream intron. The mutated locus is expected to encode a transcript which would not be translated or would be translated into non-functional, non-membranous, and presumably unstable, protein. Two sets of primer pairs specific for the wild-type (primers 1 and 2) (SEQ ID NO:1 and SEQ ID NO:3 respectively) or targeted mutant (primers 1 and 3) (SEQ ID NO:1 and SEQ ID NO:2 respectively) alleles were used to screen genomic DNA by PCR as described in heterozygous and F2 homozygous mutant animals are shown. Immunoblot analysis of hepatic membranes (50 μg protein/lane) from unfasted wild-type (F1 and F2 generations), heterozygous (F1 and F2 generations) and homozygous mutant (F2 generation) male mice were performed using polyclonal antipeptide antibodies to SR-BI (approximately 82 kDa, top) or the internal control ε-COP (approximately 36 kDa). Essentially identical results were obtained using specimens from female mice) confirmation of the expected null mutation by PCR.
Three independently derived embryonic stem cell clones containing the targeted allele were injected into C57BL/6 blastocysts and two produced 24 male chimeras, of which 11 gave germ line transmission of the targeted SR-BI allele when crossed to c57BL/6 females. F1 offspring were either homozygous (+/+) for the wild type allele or heterozygous (+/−) with both mutant and wild-type PCR products. F1 heterozygotes should be isogenic with the F1 wild-type controls except at the SR-BI locus. Wild-type, heterozygous and homozygous mutant F2 generation offspring, whose phenotypes are subject to genetic background variability, were generated from F1 intercrosses. In the F2 progeny analyzed to date (n=317), the observed ratios of wild-type heterozygous mutant homozygous mutant offspring were 1.0:1.7:0.5, values significantly different from the expected Mendelian ratio of 1:2:1 (p=0.003). Thus, there may be partially penetrant effects of the mutation either on neonatal survival or on embryonic development, which would be consistent with the distribution of SR-BI on the maternal surfaces of cells in the placenta and yolk sac during embryonic development.
All of the mutants looked normal (weight, general appearance and behavior) and the males were fertile. No offspring from female homozygous mutants have been obtained following multiple attempts to do so, indicating a substantial, and possibly complete, decrease in fertility in these females. Immunoblot analysis of liver membranes from F1 (+/+,+/−) and F2 (+/+,+/−,−/−) mice using anti-peptide antibodies which recognize the C-terminus of the SR-BI protein (anti-mSR-BI 495 ), or a segment of the putative extracellular loop (anti-mSR-BI 230 ), revealed that there was about half as much mSR-BI protein in the heterozygous mutants as in the wild-type controls and no detectable SR-BI in the homozygous mutants. No fragment or other variants of the full-length protein were detected in any of the samples. In contrast, no significant differences were observed in the levels of the control protein, ε-COP. Similar results were observed using adrenal tissue. Thus, the mutated SR-BI gene is a functionally null allele.
To determine how decreased SR-BI protein expression influenced lipoprotein metabolism, the plasma cholesterol levels in male and female wild-type and mutant mice were compared. Because there were no statistically significant differences between the data from animals derived from the two independent embryonic stem cell clones, data from these two independent sets of animals were pooled. Relative to wild-type controls there were statistically significant increases in the plasma total cholesterol concentrations of approximately 30-40% in F1 and F2 heterozygotes and 2.2-fold in F2 homozygous mutants. In contrast to the increased plasma cholesterol in the mutants, there was no statistically significant change in the levels of plasma apoA-I. These findings are consistent with the suggestion that hepatic SR-BI plays a key role in selective removal of cholesterol from circulating HDL-lower levels of hepatic SR-BI were expected to increase plasma HDL cholesterol but not directly alter apoA-I levels.
To determine if the elevated levels of plasma cholesterol in the mutants were due to changes in HDL, pooled plasma samples from F1 male and female and F2 male animals were subjected to FPLC and the total cholesterol content as well as the relative amounts of apoA-I, apoA-II and apoE in each fraction were measured. For wild-type mice (srbI +/+ ) most of the cholesterol, apoA-I and apoA-II were in the HDL fraction, with small or undetectable amounts in the VLDL and IDL/LDL fractions. There was an apparently low level of apoE which both co-migrated with the HDL and with a small cholesterol peak in the IDL/LDL region. The cholesterol and apolipoprotein profiles of the heterozygous mutants were similar to those of the wild-type controls, except that there was an increase in the amount of cholesterol in the HDL fractions and there was a tendency of the HDL peak (cholesterol and/or apolipoproteins) to be broader than that of wild-type and shifted slightly to the left, which may represent large HDL particles. This suggested that there might be a difference in the average sizes of the HDL particles due to the inactivation of one of the SR-BI alleles; however, this shift was not observed in all specimens. In the F2 homozygous mutant animals (srbI −/− ) the cholesterol was found in a large, somewhat heterogeneous peak in the HDL range, but shifted to the left (larger apparent size) of the wild-type HDL peak. The amount of cholesterol in the IDL/LDL fraction varied between samples.
Combined immunoblot analysis of fractions 23-28 from the chromatograms were performed with polyclonal antibodies to apoE, apoA-I and apoAII. Additional analysis of these and independent chromatograms established that there were no additional peaks containing apoA-I in fractions containing larger lipoproteins (fractions 1-22) and that the only other peak containing a small amount of apoE was in fraction 6, which corresponds to VLDL. The distributions of apoA-I and apoA-II were similar to that of cholesterol, although, unlike the case for apoA-I there was a notable reduction in the amount of apoA-II relative to that seen in wild type and heterozygous mutant animals. Conversely, in the homozygous mutants there was a substantial increase in the amount of apoE, whose distribution profile (larger particles, centered around fractions 26-28) differed from, but overlapped, those of apoA-I and apoA-II.
These results with the mutant animals, in which the changes in SR-BI expression are in the physiologic range, are complementary to and consistent with the observation that transient adenovirus-mediated hepatic SR-BI overexpression results in dramatically decreased levels of HDL cholesterol and increased delivery of HDL-associated lipid to hepatocytes and the bile. In rodents, most of the plasma HDL cholesterol appears to be removed by the liver via selective uptake and the liver appears to be the site of the highest total amount of SR-BI protein expression. It seems likely that buildup of large, cholesterol-enriched lipoprotein particles in the circulation of SR-BI mutants was primarily due to decreased hepatic selective HDL cholesterol uptake. Thus, it appears that murine plasma HDL cholesterol levels are particularly sensitive to physiologically relevant changes in the levels of hepatic SR-BI protein expression (e.g., approximately 50% reduction in heterozygotes). The effect of the null mutation in SR-BI on total plasma cholesterol levels was quantitatively similar to that of a null mutation in the LDL receptor. For both sets of mutants, total plasma cholesterol levels were approximately 36% above wild-type controls for heterozygotes and approximately 114% for homozygotes. It is important to emphasize that while the magnitudes of the effects on total plasma cholesterol of these distinct mutations (SR-BI vs. LDL receptor) are similar, the mechanistic consequences on lipoprotein metabolism (e.g., effects on the various lipoproteins) differ.
In addition to playing an important role in regulating plasma HDL cholesterol, SR-BI has been implicated in the delivery of HDL cholesterol to the adrenal gland and other steroidogenic tissues, both for the accumulation of esterified cholesterol stores and for steroid hormone synthesis. To examine this, the cholesterol content of adrenal glands in mutant and wild-type mice was measured. The results are shown in Table 1. As predicted, cholesterol stores in the adrenal gland dropped substantially in the heterozygous and homozygous mutants to 58% and 28% of control, respectively. It was also noted that the color of intact adrenal glands from homozygous mutants was brownish-red while that of wild-type and heterozygous animals was light yellow and, in preliminary studies, a dramatic decrease in oil red O staining of the adrenal cortex was observed in the homozygous mutants relative to the wild-type mice. Thus, the total cholesterol content, color and oil red O staining characteristics of the adrenal glands in SR-BI homozygous mutants resembled those in their cholesterol-depleted counterparts in other murine mutants, including null mutants in the SR-BI ligand apoA-I. This similarity with apoA-I knockouts is consistent with the possibility that the reduction in adrenal cholesterol in the SR-BI homozygotes is a direct consequence of the loss of the key receptor for selective lipid uptake. Recent antibody blocking experiments have provided additional support for a major role of mSR-BI in delivering HDL cholesterol to cultured adrenocortical cells for steroidogenesis. Based on the tissue distribution and hormonal regulation of SR-BI protein expression and the phenotypes of apoA-I knockouts, it seems likely that there would also be reductions in cholesterol stores in other steroidogenic tissues (e.g., ovary, testes) in SR-BI homozygous mutants. Adrenal cholesterol deficiency in both the apoA-I and SR-BI homozygous mutants also suggests that LDL receptors in the mouse, in which there normally is little LDL in the plasma, do not normally contribute significantly to murine adrenal cholesterol accumulation.
TABLE I
Effects of SR-BI Gene Disruption on Plasma Total Cholesterol and Apo A-I Concentrations, and Adrenal
Gland Total Cholesterol Content in Wild-type (srbI +/+ ), Heterozygous (srbI +/− ),
and Homozygous (srbI −/− ) Mutant Mice.
F1 Generation
Plasma Total
Plasma Total
F2 Generation ξ
Adrenal Gland Total
Cholesterol
Cholesterol
Plasma ApoA-1
Cholesterol
srbl
% of
% of
% of
μ/mg
% of
genotype
gender
mg/dl
control
mg/dl
control
mg/dl
control
protein
control
+/+
Male
93 ± 8(29)
100
99 ± 12(18)
100
—
—
—
—
Female
80 ± 7(13)
100
94 ± 20(27)
100
—
—
—
—
Both
89 ± 10(42)
100
96 ± 17(45)
100
25 ± 3(10)
100
128 ± 28(5)
100
+/−
male
126 ± 10(21)
100
137 ± 21(29)
100
—
—
—
—
female
112 ± 9(23)
140
118 ± 9(49)
112
—
—
—
—
Both
126 ± 12(44)
134
126 ± 22(78)
131
28 ± 2(12)
112
74 ± 18(6)
58
−/−
male
—
—
220 ± 41(10)
222
—
—
—
—
female
—
—
209 ± 32(7)
222
—
—
—
—
Both
—
—
216 ± 37(17)
225
27 ± 3(11)
—
36 ± 7(5)
28
Values for F1 generation represent mean ± standard deviation. Values for F2 generation in parenthesis represent the numbers of animals analyzed. Values for plasma total cholesterol determined with an Autoanalyzer and human apoA-I standards. F1 generation animals were not fasted. F2 generation animals were not fasted prior to analysis of adrenal gland cholesterol levels but were fasted for 4-8 h prior to analysis of plasma.
EXAMPLE 2
Loss of SR-BI Expression Leads to the Early Onset of Occlusive Atherosclerotic Coronary Artery Disease, Spontaneous Myocardial Infarctions, Severe Cardiac Dysfunction, and Premature Death in Apolipoprotein E-Deficient Mice
Murine models of atherosclerosis, such as the apolipoprotein E (apoE) or the LDL receptor knockout mice, usually do not exhibit many of the cardinal features of human coronary heart disease (CHD), eg, spontaneous myocardial infarction, severe cardiac dysfunction, and premature death. Mice with homozygous null mutations in the genes for both the high density lipoprotein receptor SR-BI and apoE (SR-BI/apoE double knockout [dKO] mice) exhibit morphological and functional defects with similarities to those seen in human CHD. When fed a standard chow diet, these hypercholesterolemic animals developed significant atherosclerotic lesions in the aortic sinus as early as 4 to 5 weeks after birth. They also exhibited extensive lipid-rich coronary artery occlusions and spontaneously developed multiple myocardial infarctions and cardiac dysfunction (eg, enlarged hearts, reduced ejection fraction and contractility, and ECG abnormalities). Their coronary arterial lesions, which were strikingly similar to human atherosclerotic plaques, exhibited evidence of cholesterol clefts and extensive fibrin deposition, indicating hemorrhage and clotting. All of the dKO mice died by 8 weeks of age (50% mortality at 6 weeks). Thus, SR-BI/apoE dKO mice provide a murine model for CHD and may help better define the role of lipoprotein metabolism and atherosclerosis in the pathogenesis of myocardial infarction and cardiac dysfunction. Furthermore, these animals are useful for preclinical testing of potential genetic and/or pharmacological therapies for CHD.
Materials and Methods
Animals
Mice (mixed C57BL/6×129 background) were generated at MIT and were housed and fed a normal chow diet. Unless otherwise noted, 4- to 6-week old dKO mice, apoE KO littermates, and SR-BI KO and wild type controls on the same background were studied. No significant differences were observed between males and females.
Histology
Mice were euthanized and tissues prepared for cryosectioning. Tissues for paraffin sections were immersion fixedin buffered 10% formalin (J. T. Baker). Sometimes heparin was administered (450 U/20 g, IV) prior to euthanasia to prevent coagulation. Tissue sections were stained with Masson's trichrome (Sigma), hematoxylin, and eosin (H&E) or Oil red O and hematoxylin. Immunohistochemistry was performed using anti-fibrin (NYB-T2G1, 1 _g/mL, Accurate Chemical & Scientific Corp) or anti-macrophage (F4/80, MCA 497, Serotec, diluted 1:10) antibodies using M.O.M. immunodetection (AEC substrate) or Vectastain Elite ABC (diaminobenzidine substrate) kits (Vector), respectively, with hematoxylin counter-staining.
Gravimetry
Mice were euthanized, weighed, and perfused, and intact hearts or the right ventricular (RV) free wall and the left ventricle (LV)_septum (LV_S) were dissected and weighed.
Magnetic Resonance Imaging (MRI)
Mice were anesthetized (chloral hydrate, 200 to 320 mg/kg IP; Sigma) and placed in a 2T small bore magnet (Bruker Instruments) on a custom body coil containing ECG electrode patches. Heart rates were adjusted to approximately 300 bpm with 1% to 2% isoflurane. Scout, long-axis, and 6 to 7 1-mm thick short-axis images were collected. Short-axis images spanning the entire heart were used to measure LV tissue volume, LV end diastolic and end systolic luminal volumes (LVEDV and LVESV), and ejection fractions (EF_((LVEDV_LVESV)/LVEDV) — 100%).
Hemodynamic Evaluation
Mice were heparinized (1 U/10 g IP), anesthetized with chloral hydrate as above, intubated, and ventilated (Harvard Apparatus, Inc) with room air (130 breaths/min; tidal volume: approximately 15 μL/g). Lidocaine HCL (0.5%; Abbott) was administered locally. The right carotid artery was exposed and a 1.4 Fr micromanometer catheter (Millar Instruments) was advanced into the aorta and then the LV for pressure measurements. LV pressures were measured before and after cutting both vagal nerves. Data were recorded using a Windaq DI 220 converter and analyzed using Windaq Pro software (Dataq Instrument) with some manual intervention to correct for micromanometer drift and insure proper evaluation of LVEDP.
Angiography
After median sternotomy, cannulation of the ascending aorta (PE50 polyethylene tubing: Becton Dickinson and Company), and opening the right atrium for drainage, each heart was harvested, flushed with PBS, and barium sulfate (E-Z-EM, Inc) was injected manually at a maximum pressure of 80 mm Hg. Angiograms were obtained with a Micro 50 (General Electric, 20 kV, 20-second exposure). Only the left coronary arterial network could be routinely observed.
Electrocardiography
For avertin-anesthetized mice, ECGs were recorded using 6 standard limb leads with a Silogic EC-60 monitor (Silogic Design Limited). For conscious mice, ECGs were recorded using AnonyMOUSE ECG Screening Tools (Mouse Specifics, Inc).
Statistical Analysis
A value of P<0.05 was considered significant (2-tailed, unpaired Student's t test or ANOVA test, StatView).
Results
SR-BI/apoE double KO mice (dKO mice) fed a standard low fat/low cholesterol diet develop extensive aortic sinus atherosclerosis by 5 weeks of age and die prematurely. All of the dKO mice died between 5 to 8 weeks of age (50% mortality at 6 weeks). No control mice died during this period. Before death, the dKO mice exhibited a 1- to 2-day period of progressively reduced activity and altered appearance (ruffled fur, abnormal gate, and occasionally labored breathing).
Extensive Myocardial Fibrosis
dKO hearts were enlarged relative to controls (eg, apoE KO) and exhibited pale, discolored patches not seen in any controls, suggesting extensive MI and scarring. These lesions were always present in the atrioventricular (AV) groove of the left ventricle and frequently present at various locations on the right ventricular (RV) wall, the LV wall, and/or the apex. Regions surrounding the mitral valves (not the valves themselves) and the LV outflow tract were invariably fibrotic. Higher magnification views and show lesions contained fibrotic connective tissue, few remaining myocytes, and numerous large, dilated, apparently mononuclear inflammatory cells, some of which were macrophages. Lesions in the RV free wall and more apical regions appeared more well-organized and contained fewer dilated cells than those in the outflow tract area and were characterized by extensive fibrosis, inflammation, and in some cases, diffuse necrosis and myocardial scarring typical of healed infarcts. Numerous macrophages were detected in these lesions and lesions in the papillary muscle. Thus, macroscopic and microscopic observations revealed multiple MIs in the dKO mice. In hypercholesterolemic animals, macrophages can accumulate extensive cytosolic lipid deposits (foam cells). Neutral lipid staining (oil red O) of dKO hearts was particularly intense in macrophage-rich, fibrotic regions and appeared both in a concentrated, intense, globular pattern reminiscent of intracellular lipid and in a punctate pattern reminiscent of extracellular lipid. More diffusely distributed lipid was detected in non-fibrotic tissue throughout the heart between myocardial fibers. The codistribution of lipid and macrophages suggested the presence of macrophage foam cells. Future studies will determine if macrophage infiltration into fibrotic lesions is a consequence of and/or contributes to lesion development and if these lesions are similar to those in human inflammatory cardiomyopathies.
Heart Function
Intact hearts and LVs_septa (LV_S) and RVs from dKO mice were larger than those from age-matched controls (1.6- to 1.8-fold greater mean heart-to-body weight ratios). Furthermore, dKO mice had a significantly lower body weight (15.3:2.0 g) than control animals (wild type: 20.7:4.3 g; SR-BI KO: 21.3:3.8 g; apoE KO: 18.8:2.3 g. P<0.002). This was confirmed by MRI analysis of LV_S tissue volume. Increased tissue volume reflects a thicker LV_S wall (assuming no change in ventricular length). In contrast, the body weight-corrected LVEDVs were only slightly higher for dKO hearts, suggesting only minor dilation. Thus, the increased size of dKO hearts was due primarily to increased ventricular tissue mass, possibly resulting from thickening of the wall near the outflow tract and compensatory thickening of the ventricular wall in response to reduced contractility. Hemodynamic analysis revealed that aortic systolic blood pressure and heart rate (HR) were significantly lower in dKO than in control mice. dKO mice also had substantially lower LV systolic pressure (LVSP) and contractility (_dP/dt), indicating LV systolic dysfunction. A similar (3-fold) reduction in _dP/dt indicated impaired LV relaxation. The somewhat lower HR of dKO mice relative to controls (not observed in non-anesthetized mice) was not due to extracardiac neuronal influences (bilateral disruption of the vagal nerves did not eliminate the HR differences). Although reduced HR might have contributed to reduced blood pressure and contractility, and might complicate interpretation of differences in dP/dt values, it is unlikely that these relatively small baseline differences caused the large changes in both _dP/dt and _dP/dt. Furthermore, values for the products of pressures (P) with either _dP/dt or _dP/dt showed the same trends, indicating a minimal or insignificant influence of pressure on dP/dt values. The decreased aortic blood pressures and abnormal contractility and relaxation in these dKO mice are consistent with primary cardiac dysfunction. Carotid arterial blood pressure was measured in dKO mice (n=3) and control littermates (apoE KO mice with a heterozygous null mutation in SR-BI, n=3) at 3 (chloral hydrate anesthesia, 0.2 mg/g) and again at 4 (urethane anesthesia, 1 mg/g) weeks of age. No blood pressure differences at 3 weeks and only a slight relative reduction in the dKO mice at 4 weeks. Thus, it is unlikely that hypertension was responsible for the ventricular hypertrophy or other cardiac defects exhibited by dKO animals. MRI images at end-diastole or end-systole show that, whereas the LVEDVs were similar, the LV end systolic volumes (LVESVs) were substantially higher in dKO hearts than in the controls. Consequently, the ejection fractions of the dKO hearts, a critical measure of heart function, were substantially lower (approximately 50%) than those of controls. In unanesthetized, conscious mice, normal ECG patterns were seen in controls, whereas striking abnormalities were observed in 6 of 12 dKO mice. One exhibited an ST elevation of unclear etiology, and 5 showed severe ST depression, indicating subendocardial ischemia. 14,16 In 5 of 8 dKO mice, but not in any controls.
TABLE II
Hemodynamic Analyses of Heart Function in Control and dKO Mice
Aortic
Aortic
Diastolic
Systolic
Pressure,
Pressure,
LVEDP,
LVSP,
+dP/dt.
−dP/dt,
Heart Rate,
Genotype
mm Hg
mm Hg
mm Hg
Mm Hg
Mm Hg/s
mm Hg/s
bpm
Wild type
61 ± 17(6)
86 ± 17(6)
5.7 ± 0.9(6)
88 ± 17(6)
3800 ± 900(6)
−3400 ± 800(6)
509 ± 71(6)
SR-BI KO
55 ± 22(5)
79 ± 20(5)
7 ± 4.4(3)
73 ± 11(3)
3200 ± 900(3)
−2900 ± 600(3)
565 ± 122(5)
ApoE KO
52 ± 12(5)
77 ± 9(5)
6.1 ± 1.7(5)
82 ± 7(5)
3500 ± 500(5)
−3300 ± 500(5)
524 ± 77(5)
DKO
39 ± 6(6)
54 ± 5(6)†
9.6 ± 2.2(6)
40 ± 19(6)†
1100 ± 500(6)‡
−1100 ± 400(6)‡
390 ± 39(6)
P(ANOVA)*
0.1
0.005
0.49
0.0002
<0.0001
<0.0001
0.01
Data shown here were obtained before cutting the vagal nerves (see Materials and Methods). LVEDP indicates LV and diastolic pressure; LVSP, LV systolic pressure. Values represent mean_1 SD. Numbers of animals per group are indicated in parentheses.
*ANOVA test of probability that all samples belong to the same group.
†, ‡Pairwise comparisons with each of the controls by unpaired Student's t test; †P_0.03 and ‡P_0.003.
To determine if occlusive coronary artery disease may have contributed to cardiac dysfunction, ex vivo angiography was performed. No obvious defects were apparent in control hearts (wild type, n=4; apoE KO, n=4, and SR-BI KO, n=3). Five of seven dKO hearts examined showed stenoses and occlusions of branches of the left coronary arteries, and there were two instances of apparent stenoses in the main coronary arteries. Histological analyses of dKO hearts revealed extensive coronary artery disease (CAD). There were complex occlusions of major arterial branches in the LV free wall (9 of 10 mice analyzed), the septum (10 of 11), and the RV wall (11 of 12). No occlusions were seen in age-matched controls. A partially cellular, lipid-rich lesion almost completely occludes the lumen of a left coronary branching artery. Fibrosis and inflammatory cells surrounding an occluded artery in the RV wall of another dKO mouse. Proximal lesions in coronary ostia were also seen in 7 of 10 dKO mice. These complex lesions are probably responsible for the patchy MIs in the LV and RV. Serial cross-sections through an occluded coronary artery from another dKO mouse. Trichrome and lipid staining revealed numerous cholesterol clefts within a lipid-rich, acellular, potentially ‘necrotic’ core. Frequently, a substantial portion of the lesions appeared to be acellular, and some of these amorphous regions stained blue with trichrome, suggesting the presence of collagen. Immunostaining showed fibrin deposits in the core regions of 8 of 10 lesions observed in 3 of 3 dKO mice but not in age-matched apoE KO controls (n=3). This thrombosis may be a consequence of bleeding into these complex lesions or perhaps plaque rupture.
The severe occlusive, fibrin-containing coronary arterial lesions, probable ischemia, multiple MIs, enlarged hearts, and cardiac dysfunction in very young (approximately 5 weeks old), low-fat/low-cholesterol fed SR-BI/apoE dKO mice provide a model of CHD. Combined deficiencies of SR-BI and apoE profoundly alter lipoprotein metabolism, 9 resulting in decreased biliary cholesterol and increased plasma cholesterol. The molecular mechanisms responsible for the dramatically accelerated occlusive atherosclerotic disease in the dKO mice relative to the apoE KO mice may include (1) changes in plasma proatherogenic and antiatherogenic lipoproteins, (2) altered cholesterol flux into or out of the artery wall, and (3) decreased RCT. SR-BI has also recently been shown to mediate HDL-dependent endothelial nitric oxide synthetase activation in vascular endothelium and the cellular uptake from lipoproteins of vitamin E, which can inhibit atherosclerosis in apoE KO mice.30-32 Loss of these activities may contribute to the accelerated atherosclerosis in dKO mice. The occlusive lesions in coronary arteries of SR-BI/apoE dKO mice were highly complex, containing cholesterol clefts and fibrin deposits. The occlusive lesions in SR-BI/apoE dKO mice apparently result in ischemia and the formation of multiple patchy MIs with variable sizes and locations. In humans, multiple infarcts lead to a gradual decline in systolic function, first manifest under stress and later seen under resting conditions. It is striking that the young dKO mice (5 to 6 weeks old) at rest exhibit systolic dysfunction (hemodynamic and EF abnormalities). This and an abnormally high heart-to-body weight ratio indicate severe cardiac dysfunction. Furthermore, in humans with heart disease and SR-BI/apoE dKO mice, anesthesia can induce substantial conductance abnormalities (eg, brady-arrhythmias and AV blocks). Thus, these dKO mice are a useful model to investigate the mechanisms underlying the development of complex CAD and MI. They should also be useful for preclinical testing of potential genetic and/or pharmacological therapies for CHD.
EXAMPLE 3
Analysis of the Abnormal Lipoproteins in SR-BI/Apo E Double Knockout Mice.
To study the effects of a lack of expression of the gene encoding the Scavenger Receptor, class B type I (SR-BI) on atherosclerosis, mice deficient in SR-BI (SR-BI KO mice) were crossed to mice deficient in apolipoprotein E (apo E KO mice), as described in Example 2. Mice deficient in both SR-BI and apo E (SR-BI/apo E double KO mice) did not survive beyond 8-9 weeks of age. Analysis of atherosclerosis in these mice revealed extensive atherosclerotic plaque in the aortic sinuses of SR-BI/apo E double KO mice at 5-7 weeks of age, at which time, no atherosclerotic plaque formation was detectable in mice deficient in either SR-BI or apo E alone. Further analysis of SR-BI/apo E double KO mice revealed that the animals died as the result of progressive heart block (major cardiac conduction defects), as revealed by changes in electrocardiograms and extensive cardiac fibrosis. These were accompanied by coronary artery atherosclerosis. Complete occlusion of coronary arteries with a lipid-poor material which appears to represent the formation of occlusive fibrin/platelet clots, strongly suggests that the mice die of myocardial infarctions due to atherosclerosis/thrombosis, just like humans.
The HDL receptor SR-BI mediates the selective uptake of plasma HDL cholesterol by the liver and steroidogenic tissues. As a consequence, SR-BI can influence plasma HDL cholesterol levels, HDL structure, biliary cholesterol concentrations, and the uptake, storage and utilization of cholesterol by steroid hormone producing cells. Homozygous null SR-BI knockout mice show that SR-BI is required for maintaining normal biliary cholesterol levels, oocyte development and female fertility. SR-BI/apoE double homozygous knockout mice also show that SR-BI can protect against early onset atherosclerosis. Although the mechanisms underlying the effects of SR-BI loss on reproduction and atherosclerosis have not been established, potential causes include changes in: i) plasma lipoprotein levels and/or structure, ii) cholesterol flux into or out of peripheral tissues (ovary, aortic wall), and iii) reverse cholesterol transport, as indicated by the significant reduction of gallbladder bile cholesterol levels in SR-BI and SR-BI/apoE double knockout mice relative to controls. Crosses between apoE KO mice, which on a chow diet spontaneously develop atherosclerosis at around 3 months of age, and SR-BI KO mice clearly show that genetically suppressing SR-BI activity in apoE KO mice dramatically accelerates the onset of atherosclerosis.
Materials and Methods
Animals
Mice (mixed C57BL/6×129 background) were housed and fed a normal chow diet. SR-BI −/− mice and apoE −/− mice (The Jackson Laboratory were mated and the double heterozygous offspring were intercrossed. The resulting SR-BI +/− ApoE −/− offspring were mated to produce single apoE KO and double SR-BI/apoE KO animals. Genotypes were determined by PCR analysis (see The Jackson Laboratory web site). Estrus cycles were followed by vaginal cytology and external appearance. Superovulation was induced by intraperitoneal injection of 5 IU each of pregnant mare's serum (Calbiochem) and human chorionic gonadotropin (Organon). Pseudopregnancy was induced by mating (confirmed by detection of vaginal seminal plug) with vasectomized males (Taconic). Ovaries were harvested and prepared for sectioning as described below, and oocytes and preimplantation embryos were harvested and cultured in KSOM medium with amino acids (Specialty Media).
Plasma and Bile Analysis
Blood was collected in a heparinized syringe by cardiac puncture from mice fasted overnight. Plasma was subjected to FPLC analysis, either immediately after isolation or after storage at 4° C. Total cholesterol was assayed. Cholesterol from non-apoB containing lipoproteins was determined either using the EZ HDL kit (Sigma, based on an antibody which blocks detection of cholesterol in non-HDL lipoproteins, and validated by us using human or mouse lipoproteins, not shown) or after precipitation with magnesium/dextran sulfate (Sigma). Plasma (0.4 μl) and FPLC fractions or pools were analyzed by SDS-polyacrylamide or agarose gel electrophoresis and immunoblotting with chemiluminescence detection using primary anti-apolipoprotein antibodies (Sigma, or gifts from J. Herz and H. Hobbs) and corresponding horseradish peroxidase coupled secondary antibodies (Jackson Immuno Research or Amersham). The Attophos chemifluorescence kit (Amersham) and an alkaline phosphatase coupled goat anti-rabbit secondary antibody (gift from D. Housman) were used with a Storm Fluorimager (Molecular Dynamics) for quantitative analysis. Plasma progesterone concentrations were determined by radioimmunoassay (Diagnostics Products Corp, Los Angeles, Calif.). Cholesterol was extracted from gallbladder bile and assayed. Histology and immunofluorescence microscopy: Mice anesthetized with 2.5% avertin were perfused through the left ventricle with 20 ml of ice cold PBS containing 5 mM EDTA. Hearts were collected directly, or the mice were perfused (5 ml) with paraformaldehyde and the hearts collected and treated. Hearts and ovaries were frozen in Tissue Tek OCT (Sakura, Torrance, Calif.). Serial cross sections (10 μm thickness through aortic sinuses, 5 μm for ovaries, Reichert-Jung cryostat) were stained with oil red O and Meyer's hematoxylin. Images were captured for morphometric analysis using a computer assisted microscopy imaging system and lesion size was quantified as the sum of the cross-sectional areas of each oil red O staining atherosclerotic plaque in a section using NIH Image software. Immunohistochemistry with a monoclonal anti-α smooth muscle actin antibody (Sigma, gift from R. Hynes) was performed). Cumulus/oocyte complexes, isolated from the oviducts of superovulated females or denuded oocytes (zona pellucida removed) were immunostained with polyclonal rabbit anti-murine SR-BI antibodies gift from K. Kozarsky) and Cy3-labeled donkey anti-rabbit secondary antibodies (gift from R. Rosenberg).
Statistical Analysis
Data were analyzed using either a two-tailed, unpaired Student t-test (total or EZ HDL cholesterol from plasma, bile or FPLC fractions, progesterone and apoA-I levels) or an unpaired nonparametric Kruskall-Wallis test (atherosclerotic plaque lesion sizes) (Statview and Microsoft Excel). Values are presented as means ± standard deviations.
Results and Discussion
To analyze the effects of SR-BI on atherosclerosis, SR-BI KO and apoE KO (spontaneously atherosclerotic) mice were crossed and the lipoprotein profiles and development of atherosclerosis in the single and double homozygous KO females at 4-7 weeks of age compared. Results for males were similar, except as noted. As reported in example 1, plasma total cholesterol in the single SR-BI KOs was increased relative to controls, because of an increase in large, apoE-enriched HDL particles, while the even greater relative plasma cholesterol increase in the single apoE KOs was a consequence of a dramatic increase in cholesterol in VLDL and IDL/LDL size particles. There was increased plasma cholesterol in the double KOs relative to the single apoE KOs, mainly in VLDL size particles. This might have occurred if SR-BI, which can bind apoB containing lipoproteins, directly or indirectly contributes to the clearance of the cholesterol in VLDL size particles in single apoE KO mice (reduced clearance in its absence).
The normal size HDL cholesterol peak seen in the single apoE KOs virtually disappeared in the double KOs. However, no statistically significant differences (P=1.0) in plasma levels of HDL's major apolipoprotein, apoA-I, were detected. Based on the analysis of lipoproteins in the single SR-BI KO mice, abnormally large HDL-like particles were expected to appear in the double KOs. Indeed, the loss of normal sized HDL cholesterol and apoA-I in the double KOs was accompanied by a shift of the apoA-I into the VLDL and IDL/LDL size fractions. Furthermore, analysis of HDL-like cholesterol in the FPLC fractions using the EZ HDL assay provides evidence for the presence of abnormally large HDL-like particles in the double KO mice. In the single apoE KO males, most of this cholesterol was in particles with the size of normal HDL, while in their double KO counterparts almost all of this cholesterol was in abnormally large particles. In addition, there was approximately 3.7-fold more of this HDL-like cholesterol in the double (133±24 mg/dl) than in the single (36±16 mg/dl, P=0.005) KO mice. These increases in the amounts and sizes of HDL-like cholesterol by inactivation of the SR-BI gene in an apoE KO background were reminiscent of those seen in a wild-type background (approximately 2.2-fold increase in cholesterol, although the HDL-like particles in the double KO mice were much larger and more heterogeneous than those in the SR-BI single KO mice. A similar trend was seen for female mice, except that there were increased levels of abnormally large HDL-like cholesterol in the single apoE KO females relative to males. Preliminary cholesterol measurements using magnesium/dextran sulfate precipitation of lipoproteins support the EZ HDL findings of large HDL in the double KO animals.
Additional evidence for abnormally large HDL-like particles in the IDL/LDL size range from both males and females was obtained using agarose gel electrophoresis and immunoblotting. There was a significant reduction in the amount of immunodetectable apoB present in the IDL/LDL-sized particles from the double KOs relative to the single apoE KOs, even though there was as much or more total cholesterol in these fractions in the double KOs. In addition, there was significantly greater heterogeneity in the electrophoretic mobilities of apoA-I containing IDL/LDL-sized particles. This was in part due to the presence of novel apoA-I containing, apoB-free, HDL-like particles. In contrast, most of the apoA-I in the single apoE KOs appeared to comigrate with apoB. Thus, it appears that normal size HDL in the single apoE KO animals was replaced by very large (VLDL/IDL/LDL-size) HDL-like particles in the double KO animals. It is possible that normal size HDL is converted into these large HDL-like particles in the absence of both apoE and SR-BI because of substantially reduced selective (SR-BI mediated) and apoE-mediated uptake or transfer of cholesterol from HDL particles.
In addition to examining plasma cholesterol, biliary cholesterol was measured in the mice. Cholesterol levels in gallbladder bile were significantly reduced in SR-BI single KO (30%, P<0.005) and SR-BI/apoE double KO (47%, P<0.0005) mice relative to their SR-BI +/+ controls. This is consistent with the previous finding that hepatic overexpression of SR-BI increases biliary cholesterol levels and indicates that SR-BI may normally play an important role in the last stage of reverse cholesterol transport—transfer of plasma HDL cholesterol into bile. The data also suggest that apoE expression can regulate biliary cholesterol content in a SR-BI KO, but not SR-BI +/+ , background.
Atherosclerosis in the animals was assessed by analyzing plaque areas in aortic sinuses and the effects of SR-BI gene disruption on plasma lipoproteins in apoE KO mice. Mice were 4-7 weeks old. Plasma apoA-I levels (right, mean±SD, expressed as relative units) were determined by SDS-polyacrylamide (15%) gel electrophoresis followed by quantitative immunoblotting for apoE −/− (n=7) and SR-BI −/− apoE −/− females (n=5) (P=0.1). Lipoprotein cholesterol profiles: Plasma lipoproteins from individual apoE −/− or SR-BI −/− apoE −/− females were separated based on size (Superose 6-FPLC) and total cholesterol in each fraction (expressed as mg/dl of plasma) was measured. Pooled Superose 6-FPLC fractions (approximately 21 μl per pool) from females in an independent experiment were analyzed by SDS-polyacrylamide gradient (3-15%) gel electrophoresis and immunoblotting with an anti-apoA-I antibody (18). Each pool contained 3 fractions and lanes are labeled with the number of the middle fraction in each pool. Average EZ HDL cholesterol FPLC profiles for apoE −/− or SR-BI −/− apoE −/− males (n=3) or females (n=3). Agarose gel electrophoresis and immunoblotting: Pooled fractions (11-21, 3.5 μl) from the IDL/LDL region of the lipoprotein profile from individual apoE −/− or SR-BI −/− apoE −/− females were analyzed using either anti-apoA-I or anti-apoB antibodies. Migration was upward from negative to positive. Gallbladder biliary cholesterol (mean±SD): Total gallbladder biliary cholesterol from both male and female mice of the indicated genotypes (n=10 or 11 per genotype) was measured. Except for the wild-type and apoE −/− values, all pairwise differences were statistically significant (P<0.025-0.0005).
To determine the effects of SR-BI gene disruption on atherosclerosis in apoE KO mice, atherosclerosis in SR-BI −/− (n=8, 4-6 weeks old), apoE −/− (n=8, 5-7 weeks old), or SR-BI −/− apoE −/− (n=7, 5-6 weeks old) female mice was analyzed in cryosections of aortic sinuses stained with oil red O and Meyer's hematoxylin as described in Methods. Representative sections through the aortic root region and cross-sectional areas of oil red O stained lesions in the aortic root region, showed average lesion areas (mm 2 ±SD) for SR-BI −/− apoE −/− , apoE −/− or SR-BI −/− mice, respectively, were as follows 0.10±0.07, 0.002±0.002, and 0.001±0.002 (P=0.0005). Also see Table II quantitative analysis of females; qualitative analysis of a smaller sample of males gave similar results. There were virtually no detectable lesions in the single KO animals at this relatively young age (4-7 weeks). However, there was substantial, statistically significant, lesion development in the double KOs in the aortic root region, elsewhere in the aortic sinus (Table II), and in coronary arteries. The lipid-rich lesions were cellular (hematoxylin stained nuclei were seen at high magnification) and in some cases had a cellular cap which stained with antibodies to smooth muscle actin. Thus, the atherosclerotic plaques were relatively advanced.
Potential causes of the dramatically accelerated atherosclerosis in the double KOs include: i) changes in relative amounts of cholesterol in proatherogenic (e.g., increased VLDL sized or abnormally large HDL-like particles) and antiatherogenic (e.g., loss of normal HDL) lipoproteins, ii) altered flux of cholesterol into or out of the aortic wall, perhaps directly due to SR-BI-mediated efflux (17, 38, 39), iii) decreases in RCT, suggested by the generation of abnormally large, HDL-like particles and decreased biliary cholesterol levels due to absence of hepatic SR-BI activity, and iv) changes in other metabolic/organ systems which might influence the cardiovascular system. For example, there was significant accumulation of oil red O staining lipids in other tissues, including the myocardium, in the double, but not single, KO animals. In addition, at 5-6 weeks of age when the double KOs were studied, they were somewhat smaller (approximately 20% lower weight) than single apoE KO controls.
While most did not exhibit overt signs of illness at that time, they all died suddenly around 8-9 weeks of age. Electrocardiographic studies indicated that premature death of the double KOs was due to progressive heart block (cardiac conduction defects) and histology revealed extensive cardiac fibrosis and narrowing or occlusion of the coronary arteries, suggesting myocardial infarction (MI) due to advanced atherosclerotic disease.
The anti-atherosclerotic effect of SR-BI expression in apoE KO mice is consistent with the reports that adenovirus- or transgene-mediated hepatic overexpression of SR-BI in the cholesterol and fat-fed LDLR KO mouse reduces atherosclerosis. Thus, pharmacologic stimulation of endogenous SR-BI activity may be antiatherogenic, possibly because of its importance for RCT. The accelerated atherogenesis and loss of normal size HDL cholesterol in the double KOs resembles that reported for high-fat diet fed single apoE KO mice; although those mice have far higher total plasma cholesterol levels (1800-4000 vs. approximately 600 mg/dl). It is theought the similarities arise in part because the very high levels of large lipoproteins in the fat-fed single apoE KO might block the ability of SR-BI to interact with HDL and other ligands (functional SR-BI deficiency due to competition), or because of dietary suppression of hepatic SR-BI expression.
TABLE II
Average lesion sizes in the aortic sinuses of mice deficient in SR-BI, apoE, or both.
Mean lesion size (mm 2 )*
Valve Attachment
Genotype
Aortic Root
Partial Valve Cusps
Sites
Proximal Aorta
Overall Mean‡
SR-BI −/−
0.001 ± 0.002(8)
0.0003 ± 0.0008(8)
0 ± 0(8)
0 ± 0(6)
0.0004 ± 0.001(6)
apoE −/−
0.002 ± 0.002(9)
0.0006 ± 0.0009(9)
0.001 ± 0.002(9)
0.0002 ± 0.0003(9)
0.001 ± 0.002(9)
SR-BI −/−
0.10 ± 0.07(7)
0.07 ± 0.07(7)
0.02 ± 0.01(6)
0.02 ± 0.02(6)
0.04 ± 0.04(6)
apoE −/−
P value†
0.0005
0.006
0.002
0.003
0.001
*Values are the means ± SD (number of animals indicated in parentheses).
‡Means of combined values from the regions of the aortic root partial valve cusps, valve attachment sites and proximal aorta.
†Lesion sizes in each region were compared using the Kruskall-Wallis test
EXAMPLE 4
Prevention or Treatment of Atherosclerosis in SR-BI Knockout Mice
The animals described in the proceeding examples are useful to screen for compounds that are effective for the prevention or treatment of atherosclerosis and heart disease. Several studies were conducted to demonstrate this.
Materials and Methods
Animals
Mice were housed and fed a normal chow diet or chow (Teklad 7001) supplemented with 0.5% (wt/wt) 4,4′-(isopropylidene-dithio)-bis-(2,6-di-tertbutylphenol (probucol; Sigma Chemical Co., St. Louis, Mo., USA). Mouse strains (genetic backgrounds) were: wild-type and SR-BI KO (both 1:1 mixed C57BL/6×129 backgrounds), apoA-I KO (C57BL/6; The Jackson Laboratory, Bar Harbor, Me., USA). Double SR-BI/apoA-I KO mice were produced by (a) mating SR-BI KO males with apoA-I KO females, (b) transferring the resulting embryos into Swiss Webster recipients, and (c) intercrossing the double heterozygous offspring. Colonies were maintained by crossing double-KO males with females heterozygous for the SR-BI null mutation and homozygous for the apoA-I mutation to optimize the low yield of SR-BI homozygotes.
Results
Effects of Genetic Disruption of the apoA-I Gene or Probucol Treatment on the Fertility of Female SR-BI KO Mice
Wild-type males were mated with female SR-BI KO (n=13, average litter size=1, 2- to 6-month mating), SR-BI/apoA-I KO (n=17, dark gray bars, average litter size=2.2, 4-month mating), probucol-fed SR-BI KO (n=14s, average litter size=5.7, 1- to 2-month mating), and probucol-fed wild-type (n=9, white bars, average litter size=5.3, 1- to 2-month mating) mice.
In the first study, PROBUCOL was fed to a mating pair (Apo E−/− and SR-BI+/−). The offspring, who have had PROBUCOL since conception, were weaned at three weeks of age. They continued to receive PROBUCOL in the chow. At 6 weeks, when typically 50% of the animals are dead in the absence of treatment, there is no abnormal phenotype, as measured by MRI of heart function, ECG, echocardiogram, and histology. There is no evidence of atherosclerosis.
At 7-8 months, most of the animals receiving PROBUCOL are still alive. However, they do have substantial atherosclerosis and some myocardial infarctions. In contrast, normal wild-type mice show no evidence of heart disease or atherosclerosis.
In a second study, animals receiving PROBUCOL were taken off of the treatment at six weeks of age. All of the animals die within 10-12 weeks.
In a third study, the animals were not treated with PROBUCOL until either weaning (three weeks of age) or approximately 4½ weeks of age (average age of death is six weeks of age). They were then fed PROBUCOL. One-half of the animals not receiving PROBUCOL until 4½ weeks of age die within a few weeks. The majority of those fed PROBUCOL at weaning survive a few months.
These results demonstrate that drugs can be used as preventatives as well as therapeutics.
Modifications and variations of the methods and materials described herein will be obvious to those skilled in the art and are intended to be encompassed by the following claims. The teachings of the references cited herein are specifically incorporated herein. | Transgenic animals that do not express functional SR-BI and ApoE develop severe atherosclerosis, by age four weeks in transgenic mice. Moreover, these animals exhibit progressive heart dysfunction by as early as age four weeks, and die by age nine weeks. This animal model has now been demonstrated to be useful as a screen for compounds which alleviate the symptoms of atherosclerosis and heart disease. Animals (Apo E−/− SR-BI+/−) were fed PROBUCOL beginning at the time of mating. Offspring are weaned at three weeks and fed PROBUCOL. In contrast to animals (Apo E−/− SR-BI−/−) not fed PROBUCOL, 50% of whom are dead at six weeks, all animals (Apo E−/− SR-BI−/−) on PROBUCOL have a normal phenotype (MRI of heart function, ECG, echocardiogram, histology) at six weeks. At seven to eight months, there is evidence of atherosclerosis and some myocardial infarction. This demonstrates that the compound has a preventative action. Animals who are taken off of the PROBUCOL all die within ten to twelve weeks. In another study, the majority of animals whose parents were not fed PROBUCOL, but who received the PROBUCOL beginning at about five weeks of age, survived for a few months, demonstrating that the compound also has a therapeutic benefit. | 8 |
[0001] This is a Continuation of International Application PCT/DE00/02855, with an international filing date of Aug. 22, 2000, which was published under PCT Article 21(2) in German, and the disclosure of which is incorporated into this application by reference.
FIELD OF AND BACKGROUND OF THE INVENTION
[0002] The invention relates generally to a device for inspecting a three-dimensional structure and more particularly to a device for inspecting three-dimensional printed circuit boards. The invention additionally relates to a surface structure inspection method.
[0003] A conventional device for inspecting a three-dimensional surface structure is known from German Patent Specification DE 196 08 468 C2. The device described in this German patent specification is suitable for inspecting a three-dimensional surface structure of a substantially flat test piece. In particular, the device is directed to inspecting the solder paste printing on printed circuit boards. Using an optical sensor, a partial area of the surface of the test piece is measured in three dimensions. A positioning device is used to position the optical sensor relative to the test piece, such that different partial areas of the surface are successively inspected.
[0004] One application in which the above-mentioned conventional device can be used is for inspection of the solder paste printing on printed circuit boards. To prevent potential solder defects from being transferred throughout the entire process chain in the production of electronic printed circuit boards, which would require subsequent repair of the boards at a substantial cost, the solder paste printing process must be constantly monitored. Monitoring the printing process enables the detection of defects caused by screen printing prior to the insertion of components on the printed circuit board and segregation of defective boards before additional costs are incurred.
[0005] Printed circuit boards for surface-mounted components, so-called surface mount technology (SMT) boards, are produced in large quantities and with many variations. The surface mounted components are fixed to the printed circuit board by soldering their terminals to “metallized” surfaces, referred to as pads, and are thereby also electrically connected with the printed conductors on the printed circuit board. For this purpose, a pattern of metallic pads corresponding to the position of the terminals of the components is provided on the printed circuit board. Solder paste is then deposited on the pads using a screen printing process. Thereafter, the surface mount component is mounted onto the printed circuit board. The component is initially held to the board by the adhesive property of the solder paste. Subsequently, after heating the printed board assembly, the terminals of the components are permanently soldered to the pads.
[0006] In the area of packaging technology, the trend is toward ever-increasing integration of the components with an increasing number of terminals per component housing. In the so-called fine-pitch range, the distance between two adjacent component terminals is approximately 1/40 of an inch. As a result, the pads on the printed circuit boards are also becoming smaller and more dense. About 80 percent of solder defects in the fine-pitch range are caused by solder paste printing. Examples of such defects are: insufficient solder paste deposit and short-circuits between adjacent pads due to inexact placement of the screen printing template during solder paste printing. To detect these defects, and to locate weak points in the production process, the printed circuit board is optically inspected after the solder paste has been deposited.
[0007] A second conventional device, described in German patent application number 199 15 052.4, comprises a device for inspecting a three-dimensional surface structure and a process for calibrating the device. This conventional inspection device is distinguished by improved accuracy in measuring three-dimensional surface structures. According to German patent application number 199 15 052.4, the coordinates of the characteristics to be inspected, particularly the solder deposit on printed circuit boards, can be derived from the mounting data of the components, which are normally available in the form of an electronic file after the design process of the components has been completed on a CAD design tool. One drawback to this conventional device, however, is that the user must manually calculate limit values for the geometric properties or the characteristics of the solder paste deposit and enter these values into the inspection device using a keyboard. In addition, the operator must manually enter the values for adjustments during any setup process. This work is very time-consuming and thus costly.
OBJECTS OF THE INVENTION
[0008] One object of the present invention is to provide a device and method for inspecting a three-dimensional surface structure in which the definition of limit values to which the measured values of the geometric properties of an inspected surface structure must conform is simplified for the operator.
SUMMARY OF THE INVENTION
[0009] To attain the above and other objects, a novel device and method in accordance with the present invention are proposed.
[0010] In accordance with one embodiment of the invention, a device is provided for inspecting a three-dimensional surface structure of a substantially flat test piece, the device includes an optical sensor operable to detect, in three-dimensions, at least a partial area of the surface of the test piece, a positioning device operable to position the optical sensor and the test piece relative to one another, a first memory operable to store setpoint values associated with geometric properties of the surface structure, a second memory operable to store tolerance values indicating a relative tolerance range for the geometric properties, an arithmetic logic unit operable to calculate limit values of an absolute tolerance range, and a display unit operable to display a defect if a measured value of at least one of the geometric properties of at least one of the inspected surface structures does not fall within a respective range of the absolute tolerance range.
[0011] In accordance with another embodiment of the invention, a surface structure inspection method is provided that includes generating a measured value by measuring a geometric property of a three-dimensional surface structure, calculating a limit value of an absolute tolerance range from a stored setpoint value for the geometric property and a stored relative tolerance value for the geometric property, comparing the measured value and the limit value, and generating a defect indication if the measured value fails to lie within the limit value.
[0012] In accordance with another embodiment of the invention, a device for inspecting the surface of a three-dimensional structure is provided which includes a first memory operable to store setpoint values for geometric properties of the three-dimensional structure, a second memory operable to store relative tolerance values corresponding to the setpoint values, and a logic unit operable to automatically calculate absolute tolerance values for the geometric properties, wherein the absolute tolerance values are based on respective values of the stored relative tolerance values and the stored setpoint values.
[0013] Also, a device and method in accordance with an embodiment of the present invention has the advantage that the process of defining the limit values, as discussed above, requires substantially less time than the time required for conventional devices. Accordingly, inspection of the solder paste printing on printed circuit boards in accordance with the present invention is less costly.
[0014] According to one embodiment, the limit values of the geometric properties of the solder paste deposit are calculated by a computer program that can be integrated into the control computer of the inspection device. As a result, the user of the inspection device is no longer required to perform time-consuming manual calculations.
[0015] A device and method in accordance with this embodiment of the present invention is advantageous particularly for inspecting the solder paste deposit on a printed circuit board. One reason this advantage is realized is because this type of inspection requires inspection of many different geometric properties and, thus, many different limit values need to be calculated.
[0016] According to one variant of the present embodiment, the operator can track the execution of the inspection program and the results of the individual inspection steps with an output device that outputs the measured values of the geometric properties of an inspected surface structure. For example, a display screen displays the measured values of the geometric properties and for those values that fall outside their absolute tolerance range, the values can be highlighted on the screen, particularly by their color, in contrast to the measured values of other geometric properties that fall within their absolute tolerance range. Accordingly, the operator's attention is drawn directly to any possible defects.
[0017] According to a further embodiment, automatic correction of the limit values is advantageously achieved by (i) an input unit that the operator can use to specify whether a measured value of a geometric property that falls outside the absolute tolerance range should be evaluated as a defect and by (ii) an arithmetic logic unit that will adapt the absolute tolerance range of the geometric property according to the measured value if that value is not evaluated as a defect. This correction ensures ready adaptability of the inspection to any changes in the parameters of a production process. The operator is relieved of the manual entry of many numbers during the setup process. Also, the new limit values can be used as the basis of subsequent inspection steps.
[0018] To improve the decision basis for the subjective evaluation by the operator, a height image of the surface structure to be inspected may be recorded with the optical sensor and displayed on a screen. The height image is characterized by a particularly useful graphical appearance on the screen. The operator thus has access to all the information contained in the height image. As a result, the operator has a better decision basis than he or she would have had if the decision were based solely on the values of the optical properties of the surface structure to be inspected as measured by other image analysis processes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention as well as embodiments and advantages thereof will now be described in greater detail with reference to the figures, in which:
[0020] [0020]FIG. 1 is a diagrammatic view of an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] An inspection device, the principle structure of which is depicted in FIG. 1, can be integrated into a printed circuit board production line. Uninspected printed circuit boards are fed to the inspection device by a conveyor belt 1 . A tippable stopper 2 , the hidden parts of which are indicated by dashed lines, holds each printed circuit board 3 to be inspected in an inspection position. After inspection is complete, the stopper 2 is downwardly retracted and the printed circuit board 3 is transported out of the inspection device by a conveyor belt 4 and to another processing station (not shown) by a conveyor belt 5 .
[0022] In practice, several printed circuit boards are usually combined in a panel and are jointly moved within the production line by a conveying mechanism. FIG. 1 shows only a single circuit board 3 , for the sake of clarity. However, it is recognized that the device depicted in FIG. 1 could also operate on a panel of combined printed circuit boards.
[0023] The axes of the machine coordinates of the inspection device are indicated by arrows X and Y. The orientation of arrow Y is at a right angle to arrow X and points into the drawing plane. Above printed circuit board 3 , there is a sensor unit 6 including an optical sensor 7 , which is embodied here as a confocal microscope, and a CCD camera 8 . To enable the sensor unit 6 to be positioned over any point on the printed circuit board 3 for the inspection of the features to be inspected, the sensor unit can be displaced in the X direction on a guide shaft 9 . A printed circuit board holder is arranged on a carriage 12 , which is supported on two shafts 10 and 11 so as to be displaceable in the Y direction.
[0024] Drive motors (not shown) of the sensor unit 6 and the carriage 12 are controlled by a position control unit 13 in such a way that they approach position setpoint values communicated on line 15 . The position setpoint values are specified by a control computer 14 . Position control unit 13 , carriage 12 and the corresponding guide shafts 9 and 10 - 11 thus constitute a positioning device with which the sensor unit 6 and the test piece 3 can be positioned in any manner relative to one another with respect to the X-Y coordinates.
[0025] To calibrate the inspection device, carriage 12 has a calibration mark 16 which is independent of the test piece 3 and is permanently connected with the inspection device. Calibration mark 16 is embodied here as a cylinder standing on a plane 17 . In this embodiment calibration mark 16 has a diameter of 1 mm and protrudes 0.4 mm above plane 17 . An upper circular surface of the calibration mark 16 is blackened, in order to improve the contrast for the gray-scale values. With the aid of the calibration mark 16 and a cross mark 18 located on the printed circuit board 3 and a second cross mark in the left rear area of the printed circuit board 3 (not shown), the optical sensor 7 and the CCD camera 8 , after calibration is complete, can be exactly positioned over the features to be inspected, and the geometric dimensions and the positions of the features can be measured.
[0026] As an example of a surface structure to be inspected, a solder deposit 19 is shown on the printed circuit board 3 . Solder deposit 19 is applied to a metallic solder pad 20 during a solder paste deposition process. An arithmetic logic unit 29 , provided with a screen display 33 and a keyboard input 34 , is used to operate the inspection device during calibration and fine adjustment processes as well as for the actual inspection process. Present states of the inspection device and the inspection results can be displayed on the screen display 33 , and the required operator inputs can be made with the aid of the keyboard 34 .
[0027] Setpoint values for geometric properties of the surface structure to be inspected are stored in a first memory 30 . In this embodiment the setpoint values include, among others, pad data, e.g., for pad 20 , which can be obtained from the CAD data of the printed circuit board 3 using a CAD converter. Since the thickness of the screen printing template used during the solder paste deposition process cannot typically be obtained from the CAD data, this data is entered as a parameter by the operator using the keyboard 34 . Also input are any required reduction factors for the template openings.
[0028] Also, the thickness of the solder resist is required for parameterizing the image processing algorithms. With this information, an edge search algorithm can, for instance, distinguish between an edge of a terminal area and an edge of the solder resist. Using the pad data and the manually entered values, the theoretical characteristics for area, height, volume and coverage of the solder paste deposit on the pads are calculated as setpoint values.
[0029] In a second memory 31 , values indicating the relative tolerance range for the geometric properties are stored. These values are assigned respectively to the individual theoretical characteristics. From the setpoint values in memory 30 and the values of the relative tolerance ranges in memory 31 , the arithmetic logic unit 29 calculates the various limit values of absolute tolerance ranges, which are stored in a third memory 32 . The memories 30 , 31 and 32 are depicted separately in FIG. 1 for the sake of clarity. In practice, these memories can be located on the same storage medium.
[0030] To simplify entry of the template data, screen 33 of arithmetic logic unit 29 displays a mask with input fields for the template thickness in micrometers, the thickness of the solder resist in micrometers, a reduction factor of the template openings in the X direction, a reduction factor of the template openings in the Y direction, a center offset of the template openings in the X direction in micrometers, and a center offset of the template openings in the Y direction in micrometers. The manually entered template data is used to calculate the theoretical characteristics of the solder paste deposit. A useful auxiliary variable in this regard is the pad area. In a rectangular pad, for instance, the pad area is the product of the pad width and the pad length.
[0031] The area of the solder paste deposit on a pad is calculated as the product of the pad width, the reduction factor in the Y direction, the pad length, and the reduction factor in the X direction. The volume of the solder paste deposit is calculated as the product of the area and the template thickness. An absolute offset of the solder paste deposit in the X direction is equal to the amount of the entered center offset of the template openings in the X direction. An absolute offset in the Y direction corresponds to the entered amount of the center offset in the Y direction. In addition, a relative offset in the X direction is calculated as a theoretical setpoint value. This setpoint value is the quotient of the entered amount of the center offset in the X direction and the pad length. A relative offset in the Y direction is calculated as the quotient of the entered amount of the center offset in the Y direction and the pad width. Pad coverage is calculated as the quotient of the solder paste deposit area and the pad area.
[0032] From the setpoint values thus determined, which are stored in memory 30 , and from the values of the relative tolerance ranges stored in memory 31 , the arithmetic logic unit 29 calculates the values of the absolute tolerance ranges, which are stored in memory 32 in the following manner. A lower limit value of the solder paste area is equal to the product of the setpoint value of the paste area and the lower limit value of the relative tolerance range assigned to the paste area. Correspondingly an upper limit value of the paste area is calculated as the product of the setpoint value of the paste area and the upper limit value of the relative tolerance range for the paste area. Absolute tolerance ranges for height as a function of template thickness and volume as a function of the setpoint value of the paste volume are determined analogously.
[0033] An upper limit value for the absolute offset in the X direction is calculated as the sum of the setpoint value of the absolute offset in the X direction and the product of the pad length and a relative tolerance value of the offset. Correspondingly, an upper limit value for the absolute offset in the Y direction is calculated as the sum of the setpoint value of the absolute offset in the Y direction and the product of the pad width and a relative tolerance value of the offset. An upper and a lower limit value of the coverage is calculated from the setpoint value of the coverage and the associated relative tolerance ranges.
[0034] Due to the variability of the production process of the printed circuit board 3 , which is not known in advance, the theoretically calculated limit values of the absolute tolerance ranges—as described above—which were stored in memory 32 must still be fine-adjusted for the inspection of the solder paste deposit. In this fine adjustment, the inspection device approaches and measures the individual surface structures to be inspected. If the inspection device detects a defect because the absolute tolerance range of a geometric property, e.g. the volume of the solder paste deposit on a pad, is exceeded, the occurrence of a defect is indicated on the screen display. In addition, the operator, by pressing a button, such as “display defect”, can request the measured values of the geometric properties and the recorded height image as well as the gray scale picture of the solder paste deposit to be displayed on the screen 33 .
[0035] The measured values that exceed the limit values of the absolute tolerance range are highlighted, e.g., by the color red, in contrast to the non-highlighted, e.g., green, values so the attention of the operator is directly drawn to these values. Based on the displayed measured values and pictures, the operator can decide whether the detected defect is a pseudo-defect or an actual defect. A defect is considered a pseudo-defect if the measured values of the geometric property must be defined as “good” or acceptable based on the variability of the production process even though the measured values fall outside the limit values of the absolute tolerance range.
[0036] The operator informs the arithmetic logic unit 29 of the inspection device of his decision by pushing a button such as “confirm error” or a button such as “ignore error” on the keyboard 34 . Pushing one of these buttons triggers either an “actual defect” counter or a “pseudo-defect” counter, respectively. In addition, if the “ignore error” button is pushed, i.e., if the detected defect is a pseudo-defect, the limit value of the absolute tolerance range, which was previously stored in memory 32 and was exceeded by the measured value, is updated in memory 32 , after a plausibility check, with a new limit value setting of the respective absolute tolerance range.
[0037] A complex manual entry of new limit values by the operator is thus not required. Furthermore, the inspection device thereafter tolerates measured values that correspond to this particular pseudo-defect. As such, the invention provides a semi-automatic training functionality of the inspection device, which largely relieves the operator from being required to make manual entries and for which the operator only needs to distinguish between pseudo-defects and actual defects. The correction of the values of the absolute tolerance range stored in memory 32 is accurately and automatically performed by the arithmetic logic unit 29 .
[0038] The above description of the preferred embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof. | An inspection device for inspecting the solder paste printing on printed circuit boards. Three-dimensional surface structures ( 19 ) are optically detected ( 7 ) and the values of their geometric properties are calculated. The values thus measured are inspected ( 29 ) for conformance to an absolute tolerance range. To fine-adjust the limit values, an operator has the option of evaluating the displayed defects as pseudo-defects, in which case the measured values are automatically accepted as the new limit values of the respective absolute tolerance range. | 6 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method causing an electronic image obtained by an electronic image forming apparatus to be supported by a transfer sheet and performing transfer printing on a surface of a fabric such as T-shirt or the like, and the transfer sheet.
2. Background Art
In recent years, a tendency of individualization of products has been specifically spreading, and wide-varieties and small-lot production of products has been inevitable. However, since the production cost is limited, how to manufacture a pattern, design and the like to be formed simply on a surface of a fabric such as a T-shirt at low cost is a major challenge. Therefore, graphics or a pattern of one's choice may be printed on the fabric surface by using an electronic image forming apparatus as a printing method configured to satisfy such a demand, reflecting a predetermined image on a thermal transfer sheet by this apparatus, placing the thermal transfer sheet on the fabric surface, and applying a pressure at a high temperature.
Incidentally, there are various printing methods of this type in the related art. For example, “A PRINTING METHOD OF AN ELECTRONIC IMAGE AND A THERMAL TRANSFER SHEET” disclosed in Japanese Patent No. 3182640 includes steps of: using two sheets: a sheet A composed of a substrate layer, a release layer, a polyvinyl acetate layer (PVA layer) or a polyester resin layer, and a sheet B composed of a substrate layer, a release layer, an adhesive layer, and a color layer; making a photocopy on a surface of either one of the sheets and forming a predetermined pattern or characters by a toner layer; stacking the both sheets one on top of another with the toner layer interposed therebetween and heating and pressing the same at a predetermined temperature; then, separating the both sheets off from each other to form the color layer and the adhesive layer of the separated sheet B on the toner layer of the sheet A; sticking the sheet A to a product such as the T-shirt and separating the substrate layer together with the release layer from the product; heating and pressing further at a predetermined temperature; and then separating and removing the polyvinyl acetate layer (PVA layer) or the polyester resin layer on the surface thereof from the product.
In other words, using the PVA layer as a medium, the medium is separated from the thermal transfer sheet substrate layer when performing transfer printing on the fabric, the medium carrying the electronic image is placed on the fabric and is pressed by heat, then the medium is separated, whereby the transfer printing of the electronic image is terminated. Therefore, the steps of separating needs to be performed twice after the transfer sheet is formed, and the toner layer of the printed electronic image is situated on the surface, so that physical property against rubbing or the like is rather inferior, and a lot of time and troubles are required.
“A METHOD OF PRINTING AN ELECTRONIC IMAGE” disclosed in Japanese Patent No. 3561775 is a method of printing characters and graphics or a pattern of white or milky white color on the surface of a color fabric such as black.
A negative photocopy of the characters, graphics, or the pattern is made on a copy sheet, the negative photocopy is superimposed on a sheet B having a release layer, an adhesive layer, and a milky white layer layered on a substrate layer and pressurized for a predetermined time under a high temperature and a high pressure. Then, by pealing the copy sheet off, the milky white layer and the adhesive layer separated from the release layer is adhered to toner and parts of the milky white layer and the adhesive layer on the side of the sheet B are removed, so that the remaining milky white layer and the adhesive layer form the characters or the graphics to be printed. Then a sheet A having a release layer and a resin layer layered on a substrate layer is superimposed on the sheet B and is pressurized for a predetermined time under a high temperature and a high pressure. Subsequently, by separating the sheet A off, the milky white layer and the adhesive layer separated from the sheet B are adhered to the surface of the resin layer on the sheet A. The sheet A is placed on a predetermined fabric surface and is pressurized for a predetermine time under the high temperature and the high pressure in the same manner, and then the sheet A is separated. Consequently, characters, graphics, or a pattern in milky white color or a white color may be printed on the fabric surface.
In other words, a positive image white adhesive material sheet as the sheet B is obtained by drawing a negative image on a normal sheet with black toner, superimposing a white adhesive material sheet as the sheet B thereon, thermally pressing the sheets, separating the sheets away from each other while the sheets are hot so that an unnecessary portion of a white adhesive material on the white adhesive material sheet as the sheet B is adhered to the black toner on the normal sheet and thus removed and only a necessary positive image remains and drawn on the white adhesive material sheet as the sheet B.
Subsequently, a transfer sheet is prepared by mirror-printing a pictorial pattern of an electronic image on the other transfer sheet A, superimposing the sheet A on the positive image white adhesive material sheet as the sheet B and thermally pressing the sheets, separating the sheet B from the sheet A, and transferring the white adhesive material layer as the positive image on the sheet B onto the pictorial pattern on the sheet A. Since the process of preparing the transfer sheet requires two times of thermal press process and aligning of the pictorial pattern on the sheet A and the positive image on the sheet B, a lot of time and troubles are required.
Problem to be Solved by the Invention
Examples of general electronic image forming apparatuses include color copying machines installed in convenience stores and color laser printers or ink jet printers sold for family use. Toner and ink of the color copying machine, color laser printers, and the ink jet printers do not include white color, and color material itself is composed of dye or pigment, transparent resin, and the like. Therefore, when a material to which the image is to be transferred is black, for example, the ink used in these printers is inferior in masking property and hence sharp images cannot be formed.
Therefore, technologies as described in the related art are used. However, in a preparation of the transfer sheet, these technologies require two times of thermal press processes or separating the medium off before the transfer printing on the material to which the image is to be transferred, and hence double work is required. These technologies are used because there is no white color and hence the masking property is not sufficient in the electronic image forming apparatus.
However, the electronic image forming apparatuses in recent years include machine types having a bottle containing transparent resin without color pigment in addition to the normal color toner or color ink bottles. Examples of the color laser printers include image PRESS C1+ manufactured by CANON Inc., in which clear toner is used as the fifth toner, and examples of ink jet printers include a glass optimizer of Colorio PX-G5300 type manufactured by Seiko Epson Corp. These functions are mounted in order to gloss over a printed result.
There is provided a method of printing an electronic image configured to allow further cutting down of the process of preparing a transfer sheet and a transfer printing work with respect to a printing workpiece in technologies of the transfer print of the related art, further cost reduction, and various types of transfer printing onto a printing workpiece simply in a short time by using the electronic image forming apparatuses as described above.
SUMMARY OF THE INVENTION
In the present invention, two types of sheets; a sheet A and a sheet B are used, and a predetermined pattern or characters are printed on either one of the sheet A and the sheet B by using an electronic image forming apparatus. As a matter of course, an ink layer or a toner layer containing a resin is formed only on parts of pattern and characters on the sheet surface. The sheet A described above is a sheet composed of a substrate layer, a release layer, a resin layer, and a porous resin layer, laminated one on top of another. The sheet B is a sheet including a substrate layer, a release layer, an adhesive layer, and a white porous resin layer having color material such as white mixed therein, laminated one on top of another.
Here, both color materials, ink composed of pigment and resin for ink jet machine and resin toner for a laser printer or for a copier are referred to as “ink/resin toner”. The above described ink/resin toner layer is formed on the porous resin layer or the white porous resin layer, and the sheet A and the sheet B are superimposed with the porous resin layer and the white porous resin layer faced each other with ink/resin toner layers formed on the surfaces thereof interposed therebetween.
In this state, the sheets are heated to a temperature in a range from 110° C. to 140° C. and pressed, whereby the ink/resin toner is softened to adhere the sheet A and the sheet B. Then, when an attempt is made to separate the sheet A and the sheet B, the separation is not started from the above-described ink/resin toner layer, but the adhesive layer of the sheet B is separated from the release layer and is adhered to the sheet A side only on the ink/resin toner layer, thereby being separated apart from each other.
In other words, the adhesive layer of the sheet B is separated at and from the release layer and transferred to the sheet A, whereby the transfer sheet A is obtained. Then, the transfer sheet A with the adhesive layer is placed on the fabric surface or the like, and is heated to a temperature in the range from 110° C. to 140° C. and is pressed. Therefore, the transfer sheet A is secured to the fabric surface or the like via the adhesive layer, and then, the transfer sheet A is peeled off. However, since a color layer is interposed under the ink/resin toner layer, the original color of the ink/resin toner is printed without being affected by the color of the fabric surface or the like to be printed. Then, a clearer and robust transfer printed material even being subject to washing may be formed on the ink/resin toner layer by being covered with the porous resin and the resin layer.
Advantages of the Invention
According to a printing method of the present invention, the two types of sheets; the sheet A and the sheet B are used, the electronic image formed of the ink/resin toner is drawn on one of the sheets, both of the sheets A and B are superimposed on one another and bought into adhesion with heat, and then are separated, so that the color layer and the adhesive layer are formed on the ink/resin toner layer.
Then, for example, since white color expression may be expressed on a black printed material by the transparent ink/resin toner, a process of forming a negative photocopy on the normal paper, forming a positive adhesive layer by aligning the same with a milky white adhesive sheet, and aligning the positive adhesive layer on the image on the sheet A is no longer necessary. In addition, since the transfer printing of the surface of the ink/resin toner layer alter the transfer is achieved by thermally pressing the transfer sheet even without separating the medium and, in addition, the ink/resin toner layer may be covered with the porous resin layer and the resin layer, the washing property is improved, so that a simple, quick and, in addition, low-cost transfer printing is enabled.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a sheet A;
FIG. 2 illustrates a sheet B;
FIG. 3 illustrates the sheet A printed by ink/resin toner;
FIG. 4 illustrates a state in which the sheet B is superimposed on the printed sheet A and is separated, so that a transfer sheet A is prepared;
FIG. 5 is a state in which the transfer sheet A is placed on a T-shirt;
FIG. 6 illustrates a state in which the transfer sheet A is separated and an ink/resin toner layer is transferred to the T-shirt in a state of being covered; and
FIG. 7 is a state in which an electronic image of the “Hinomaru” flag, i.e. the national flag of Japan is printed on a T-shirt.
DETAILED DESCRIPTION OF THE INVENTION
Embodiment 1
Examples of a substrate layer 1 of a sheet A illustrated in FIG. 1 include a paper sheet or a film. Here, on coated paper (for example, a coat 110 manufactured by Nippon Paper Industries Co., Ltd.), a release layer 2 (for example, Silicon KS3502 manufactured by Shin-Etsu Chemical Co., Ltd), a resin layer 3 (for example, a cover coat resin 300 manufactured by Goo Chemical Co., LTD), a porous resin layer 4 (for example, a mixture of FPS-2 silica manufactured by Shionogi & Co., Ltd. and a transparent urethane resin of UD710 manufactured by Dainichiseika Color & Chemicals MFG. CO., Ltd. or the like) were provided, and respective layers were laminated into a single sheet A.
Although the lamination of the sheet A was transparent, by mixing white titanium oxide as a color material, into the resin layer 3 or the porous resin layer 4 , the printed workpiece was finally covered with white and becomes white irrespective of the color of an ink/resin toner. Other color materials may also be mixed.
Examples of the substrate layer 1 of a sheet B illustrated in FIG. 2 include paper or a film. Although ST600KT manufactured by Lintec Corporation, which is processed up to the release layer 2 , may be used, here, coated paper (for example, the coat 110 manufactured by Nippon Paper Industries Co., Ltd.), the release layer 2 (for example, Silicon KS776L manufactured by Shin-Etsu Chemical Co., Ltd), an adhesive layer 5 (for example, CRISVON AH4555 manufactured by DIC Corporation), and a white porous resin layer 6 (for example, a mixture of FPS-2 silica and titanium oxide manufactured by Shionogi & Co., Ltd. and a urethane resin of UD710 manufactured by Dainichiseika Color & Chemicals MFG. CO., Ltd. or the like) were provided, and respective layers were laminated into a single sheet B. The sheet B becomes transparent if white titanium oxide, which is a color material, was not added. Other color materials may also be mixed. If the transparent ink/resin toner of the electronic image forming apparatus is the white ink/resin toner, the sheet B may remain transparent.
When “Hinomaru” (disc of the sun), which is a main portion of the Japanese national flag, was printed with a color laser printer (for example, image PRESS C1+ manufactured by CANON Inc.) on the sheet A in FIG. 1 described above, the toner layer 7 which expresses a red disc was printed, while square white part of the flag around the disc was drawn by a transparent toner layer 8 and, as illustrated in FIG. 3 , the toner layers 7 and 8 of the “Hinomaru” image of the Japanese flag of an electronic image was formed on the porous resin layer 4 on the sheet A.
Subsequently, the sheet B was superimposed on the sheet A with the above-described toner layers 7 and 8 on which the image of the “Hinomaru” flag, which is the Japanese flag, was printed with the color laser printer interposed therebetween in a state in which the porous resin layer 4 and the white porous resin layer 6 faced each other. Then, in this state, the sheets were heated to a temperature in a range from 120° C. to 130° C. and pressed at a pressure on the order of 300 g/cm 2 for 20 seconds, the toner was softened and the sheet A and the sheet B were adhered to each other. Subsequently, when an attempt was made to separate the sheet A and the sheet B, the separation was not started from the above-described toner layers 7 , 8 , but the adhesive layer 5 on the sheet B was separated from the release layer 2 , and was adhered only to a portion of the sheet A side where a “Hinomaru” (red disc) image formed of the toner layer 7 of the electronic image of the “Hinomaru” flag was drawn and to a square flag portion formed of the transparent toner layer 8 formed around the “Hinomaru” image, thereafter the layers 2 , 7 and 8 being separated apart from the release layer 2 (see FIG. 4 ).
The white porous resin layer 6 and the adhesive layer 5 on the sheet B were transferred to the sheet A, resulting in that a transfer sheet A illustrated in FIG. 4 a was formed. As illustrated in FIG. 5 , in a state that the adhesive layer 5 of the transfer sheet A was placed on the black T-shirt 9 , the sheets were heated to a temperature in a range from 120° to 130° C., and were pressed for approximately 20 seconds at a pressure on the order of 300 g/cm 2 . Thereby, the transfer sheet A was secured to the fabric surface via the adhesive layer 5 . Subsequently, when the transfer sheet A was peeled off as illustrated in FIG. 6 , a red “Hinomaru” image was clearly drawn on a white flag on the black T-shirt 9 , and the national flag of Japan 10 was printed as illustrated in FIG. 7 .
Incidentally, when 25 g of Attack ALLin (a bleaching agent with a fabric softener contained therein) manufactured by Kao Corporation was put in 30 L of warm water at a temperature of 50° C. in a dual tub washing machine of Ginga 2.2 (VH-22083) of Toshiba Corporation, and the printed black T-shirt 9 was dipped therein and was subjected to washing for 15 minutes and rinsing for 15 minutes in a strong current of washing water, and to dehydrating for 5 minutes and drying repeatedly by three times. Then, it was recognized that no color loosing and no peeling of the transferred image occurred. Also, a clothes iron for family use heated to a medium temperature of 150° C. was placed directly on the “Hinomaru” flag image 10 printed on the black T-shirt 9 and was slid laterally as is after 5 seconds, the resin toner layers 7 , 8 covered with the resin layer 3 and the porous resin layer 4 on the sheet A were not melted and the “Hinomaru” flag image 10 clearly remained on the black T-shirt 9 .
Embodiment 2
A red disc image of “Hinomaru” as of Japanese national flag was printed with ink 7 by an ink jet printer (Colorio PX-G5300 type manufactured by Seiko Epson Corp.) on the above-described sheet A illustrated in FIG. 1 , and then the sheet A was set so that the “Hinomaru” image was aligned to the center, and a square flag image which corresponds to the white portion was drawn therearound with the transparent ink 8 with an ink jet printer (Colorio PX-V630 type manufactured by Seiko Epson Corp) in which gloss optimizer manufactured by Seiko Epson Corp., which is transparent ink, was filled in all of ink bottles thereof) (See FIG. 3 ).
The ink layers 7 and 8 of the electronic image of the “Hinomaru” flag were formed on the porous resin layer 4 on the sheet A. Subsequently, the sheet B was superimposed on the sheet A in the state in which the porous resin layer 4 and the white porous resin layer 6 face each other with the ink layers 7 and 8 interposed therebetween and, in this state, the sheets were heated to a temperature in the range from 120° C. to 130° C. and was pressed for approximately for 20 seconds at a pressure on the order of approximately 300 g/cm 2 . The ink layers 7 , 8 were softened and bonded the sheet A and the sheet B to each other. Then, when an attempt was made to separate the sheet A and the sheet B, the separation was not started from the above-described ink layers 7 , 8 , but the adhesive layer 5 on the sheet B was separated from the release layer 2 and was adhered only to a portion of the sheet A side where a “Hinomaru” (red disc) image formed of the ink layer 7 of the electronic image of the “Hinomaru” flag was drawn and to a square flag portion formed of the transparent toner layer 8 formed around the “Hinomaru” image, thereafter the layers 2 , 7 and 8 being separated apart from each other (See FIG. 4 ).
The white porous resin 6 and the adhesive layer 5 on the sheet B were transferred to the sheet A, resulting in that a transfer sheet A was formed. Then, as illustrated in FIG. 5 , in a state that the adhesive layer 5 of the transfer sheet A was placed on the black T-shirt 9 , the sheets were heated to a temperature in the range from 120° C. to 130° C., and were pressed for approximately 20 seconds at a pressure on the order of 300 g/cm 2 . Thereby, the transfer sheet A was secured to the fabric surface or the like via the adhesive layer 5 . When the transfer sheet A was peeled off as in FIG. 6 , a red “Hinomaru” was clearly drawn and printed on a white flag on the black T-shirt 9 (see FIG. 7 ).
When 25 g of Attack ALLin (with bleaching agent and fabric softener contained therein) manufactured by Kao Corporation was put in 30 L of warm water at a temperature of 50° C. in a dual tub washing machine of Ginga 2.2 (VH-22083) of Toshiba Corporation, and the printed black T-shirt 9 was dipped therein and was subjected to washing for 15 minutes and rinsing for 15 minutes in a strong current of washing water, and to dehydrating for 5 minutes and drying repeatedly by three times. Consequently, it was recognized that no color loosing and separation occurred. Aso, a clothes iron for family use heated to a medium temperature of 150° C. was placed directly on the “Hinomaru” flag printed on the black T-shirt 9 and was slid laterally as is after 5 seconds, the ink covered with the resin layer 3 and the porous resin layer 4 on the sheet A was not melted and the “Hinomaru” flag 10 clearly remained on the black T-shirt 9 .
REFERENCE SIGNS LIST
1 substrate layer
2 release layer
3 resin layer
4 porous resin layer
5 adhesive layer
6 white porous resin layer
7 ink/resin toner layer
8 transparent ink/resin toner layer
9 T-shirt
10 “Hinomaru” flag | A transfer sheet is provided, whereby a T-shirt or the like can be printed in few steps by means of an electronic image forming device that uses powdered toner, liquid ink, or the like containing a plastic resin. By means of mirror-image printing a picture pattern, which is an electronic image, onto a first sheet, aligning the first sheet and a second sheet, and heat-pressing, a coating is spread over a portion of the picture pattern printed onto the first sheet. The first sheet has a structure including a mold release layer, a resin layer, and a porous resin layer in a substrate, and the second sheet includes a mold release layer, a resin layer, an adhesive layer, and a colored porous resin layer in a substrate. | 3 |
This is a division of application Ser. No. 08/272,723, filed Jul. 8, 1994, now U.S. Pat. No. 5,530,137 which is a division of application Ser. No. 08/089,523, filed Jul. 12, 1993, now abandoned, which is a division of application Ser. No. 07/861,058, filed Apr. 1, 1992, now U.S. Pat. No. 5,258,518.
BACKGROUND OF THE INVENTION
This invention relates to novel 2-substituted tertiary carbinol derivatives of 1,5-dideoxy-1,5-imino-D-glucitol and, more particularly, to the chemical synthesis of these derivatives and intermediates therefor, and to their method of inhibiting viruses such as lentiviruses.
1,5-dideoxy-1,5-imino-D-glucitol (deoxynojirimycin or DNJ) and its N-alkyl and O-acylated derivatives are known inhibitors of viruses such as human immunodeficiency virus (HIV). See, e.g., U.S. Pat. Nos. 4,849,430; 5,003,072; 5,030,638 and PCT Int'l. Appln. WO 87/03903. Several of these derivatives also are effective against other viruses such as HSV and CMV as disclosed in U.S. Pat. 4,957,926. In some cases antiviral activity is enhanced by combination of the DNJ derivative with other antiviral agents such as AZT as described in U.S. Pat. No. 5,011,829. Various of these DNJ derivative compounds also have antihyperglycemic activity. See, e.g., U.S. Pat. Nos. 4,182,763, 4,533,668 and 4,639,436.
Notwithstanding the foregoing, the search continues for the discovery and novel synthesis of new and improved antiviral compounds.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, novel 2-substituted tertiary carbinol derivatives of 1,5-dideoxy-1,5-imino-D-glucitol are provided. According to another embodiment of the invention, novel methods of chemical synthesis of these DNJ derivatives and their intermediates are provided. The novel DNJ derivatives and various of their intermediates have useful antiviral activity as demonstrated against lentivirus.
The 2-substituted tertiary carbinol derivatives of 1,5-dideoxy-1,5-imino-D-glucitol can be represented by the following general structural Formula I: ##STR1## wherein: R 4 =an alkyl, vinyl, alkenyl, alkynyl, aryl, aralkyl, alkenylalkyl, alkynylalkyl or CH 2 Y substituent having from about 1 to 10 carbon atoms;
Y=OR', SR', NR'R', or N 3 ;
R'=H or CH 3 ; and
R=H or an alkyl, aralkyl, alkenylalkyl, alkynylalkyl, aralkenyl, aralkynyl or hydroxyalkyl substituent having about 1 to 18 carbon atoms, provided that no carbon unsaturated bond is directly attached to nitrogen.
In Formula I, the alkyl moieties in the R substituents preferably are straight chain or branched alkyl groups or cycloalkyl groups which preferably have from one to about 8 carbon atoms, e.g., methyl, ethyl, propyl, isopropyl, D-butyl, iso-butyl, sec.-butyl. tert-butyl, pentyl, hexyl, heptyl, octyl, 2-ethylbutyl, 2-methylpentyl, cyclopentyl and cyclohexyl, and which can contain one or more heteroatoms, e.g. O, S, N. The alkyl moieties in the R 4 substituents preferably have from one to about 4 carbon atoms, e.g., methyl, ethyl, isopropyl and sec.-butyl. The corresponding alkenyl moieties in Formula I are, e.g., ethenyl, propenyl, butenyl, pentenyl, hexenyl, and the corresponding alkynyl moieties are, e.g., ethynyl, propynyl, butynyl, pentynyl, hexynyl, and their alkyl-substituted derivatives, e.g. methylbutenyl and methylbutynyl.
Also in Formula I, the aryl moieties in the R and R 4 substituents preferably are phenyl and substituted phenyl, e.g., lower alkylphenyl such as 2-methylphenyl and 2,4-dimethylphenyl; halophenyl such as 2-chlorophenyl, 4-chlorophenyl, 2,4-dichlorophenyl, 2-bromophenyl, 4-fluorophenyl, 2,4-difluoromethylphenyl and trifluoromethylphenyl; methoxyphenyl and nitrophenyl.
Preferred compounds of Formula I are the following:
1,5-Dideoxy-1,5-imino-2-C-methyl-D-glucitol,
1,5-Butylimino-1,5-dideoxy-2-C-methyl-D-glucitol,
1,5-Dideoxy-1,5-(3-phenylpropylimino)-2-C-methyl-D-glucitol, and
1,5-Dideoxy-1,5-(2-ethylbutylimino)-2-C-methyl-D-glucitol.
The novel synthesis of compounds of Formula I comprises the stereoselective addition of an organometallic reagent, e.g. a Grignard reagent, to the carbonyl at C-2. The substituent at C-3 strongly influences the stereochemical configuration at C-2. The unambiguous assignment of absolute stereochemistry at C-2 in these novel compounds and intermediates used in their preparation has been established by a series of NMR tests including spin decoupling. For description of these conventional techniques (e.g., NOESY and COSY), see e.g., Neuhaus and Williamson, "The Nuclear Overhauser Effect in Structural and Conformational Analysis," VCH Publishers, New York, 1989; and Martin and Zektzer, "Two-Dimensional NMR Methods for Establishing Molecular Connectivity," VCH Publishers, New York, 1988.
In accordance with a preferred embodiment of the invention, the compounds of Formula I can be chemically synthesized by the sequence of reactions shown in the following Reaction Scheme A (or 2-part Reaction Scheme B), in which the numbers in parentheses refer to the compounds defined by the generic formula shown above said numbers. R 1 , R 2 , R 3 , R 5 , X and W in Reaction Scheme A-B can be any alkyl or aryl group such as illustrated by the reactants and products described hereinafter.
In accordance with another aspect of the invention, novel pro-drugs of the antiviral compounds of Formula I are prepared by O-acylation of their free hydroxyl groups. ##STR2##
The foregoing Reaction Scheme A-B comprises the following general reaction steps:
(a) The starting material, DNJ (1), is N-acylated with an acylating agent to form an amide or carbamate derivative of DNJ (2);
(b) The hydroxyls at C-4 and C-6 are protected with a hydroxyl protecting agent by acetalization or ketalization to form an acetal or ketal (3);
(c) The hydroxyl at C-2 is selectively protected by O-acylation with an acylating agent at C-2 to give novel intermediate (4);
(d) The hydroxyl at C-3 is protected by ether formation to produce the fully protected novel derivative (5);
(e) The protecting group at C-2 is selectively removed by cleavage of ester or carbonate to give novel product (6);
(f) The free hydroxyl group at C-2 is oxidized to give novel ketone (7);
(g) The stereoselective addition of the desired R 4 is carried out by nucleophilic addition at C-2 to form the novel 2-substituted tertiary carbinol (8);
(h) The hydroxyl protecting group at C-3 is selectively removed by cleavage of ether to form novel product (9);
(i) The N-carbamate group is cleaved to give novel intermediate (10);
(j) The hydroxyl protecting group at C-4 and C-6 is removed by cleavage of acetal or ketal to give the novel intermediate (11);
(k) Intermediate (11) is N-alkylated to give the desired novel antiviral 2-substituted tertiary carbinol derivatives of DNJ, viz. compounds (12).
(l) The free hydroxyl groups in the 2-substituted tertiary carbinol derivatives of DNJ (12) can be partially or fully O-acylated to give novel compounds (13).
The sequence of steps (h), (i), (j) and (k), involving cleavage of various protecting groups to give intermediates (9), (10), (11) and (12), can be interchanged or combined.
Illustrative reaction conditions for carrying out the synthesis steps of Reaction Scheme A-B are as follows:
N-Acylation of DNJ (1) in step (a) can be carried out by conventional N-acylation procedures well known to those skilled in the art. Suitable general procedures for acylation of amines are described in U.S. Pat. No. 5,003,072; March, J. in Advanced Organic Chemistry, Wiley, New York, 1985; Patai, S. (Ed.) in The Chemistry of Amides, Wiley, New York, 1970. For example, DNJ is N-acylated to form an amide, carbamate or thiocarbamate using a variety of reagents such as acyl halides (e.g., acetyl chloride, propionyl bromide, benzoyl chloride or butyryl chloride), anhydrides (e.g., acetic anhydride, propionic anhydride or butyric anhydride), chloroformates (e.g., methyl chloroformate, ethyl chloroformate, vinyl chloroformate, benzyl chloroformate) or dicarbonates (e.g., di-tert-butyl dicarbonate). The reaction of DNJ with acyl halides is preferentially carried out in the presence of non-polar, aprotic solvents such as ethers (e.g., diethyl ether, tetrahydrofuran, dioxane, dimethoxyethane, dibutylether, tert-butyl methyl ether), chlorinated solvents (e.g., methylene chloride, chloroform, carbon tetrachloride) or hydrocarbon solvents (e.g., benzene, toluene ). However, the reaction of DNJ (1) with anhydrides, chloroformates or dicarbonates is preferentially carried out by dissolving in one or more of polar, protic solvents (such as water, methanol, ethanol) and in the presence of a base (e.g., potassium carbonate, lithium carbonate, sodium carbonate, cesium carbonate, triethylamine, pyridine, 4-dimethylaminopyridine, diisopropylethylamine, 1,8-diazabicyclo[5,4,0]undec-7-ene). N-Acylation is preferentially carried out by reacting DNJ (1) with alkyl or aryl chloroformate in solvents such as DMF or aqueous sodium bicarbonate at 20°-50° C. to give the product (2).
Protection of the hydroxyl groups at C-4 and C-6 in step (b) to give acetal or ketal derivative (3) can be carried out by conventional hydroxyl protection procedures such as those described, e.g., in U.S. Pat. No. 5,003,072 and in Green, T. W., Protective Groups in Organic Synthesis, Wiley, New York, 1981, or 2d ed., 1991. The cyclic acetals and ketals are formed by the reaction of 4,6-dihydroxy compound (2) with an aldehyde or a ketone in the presence of an acid catalyst. Illustrative carbonyl (or carbonyl equivalents such as dimethyl acetal or dimethyl ketal) compounds useful in this reaction are benzaldehyde, 4-methoxybenzaldehyde, 2,4-dimethoxybenzaldehyde, 4-dimethylaminobenzaldehyde, 2-nitrobenzaldehyde, 2,2,2-trichloroacetaldehyde (chloral) and acetophenone. The acid catalysts suitable for this reaction are, e.g., para-toluene sulfonic acid, cat. HCl, cat. sulfuric acid, FeCl 3 , ZnCl 2 , SnCl 2 and BF 3 -etherate, and the reaction is carried out in the presence of aprotic solvents such as methylene chloride, 1,2-dimethoxyethane, dioxane, dimethylformamide, acetonitrile, dimethylacetamide or dimethylsulfoxide. Thus para-toluene sulfonic acid is added to a solution of benzaldehyde dimethyl acetal in organic medium, e.g., dimethylformamide, and reacted with N-acyl-DNJ (2) at 20°-65° C. to give the product (3).
The selective protection of hydroxy group at C-2 in compound (3) in step (c) can be carried out by reaction with O-acylation forming esters (such as acetate, chloroacetate, dichloroacetate, trichloroacetate, methoxyacetate, phenoxyacetate, 4-chlorophenoxyacetate, isobutyrate, pivolate, benzoate, 4-phenylbenzoate, 4-methylbensoate, 4-chlorobenzoate, 4-nitrobenzoate, and the like) and carbonates (such as methyl, ethyl, 2,2,2-trichloroethyl, isobutyl, vinyl, allyl, phenyl, benzyl, 4-methoxybenzyl and the like) using acid chloride, anhydrides or chloroformates. The selective acylation at C-2 can be carried out by using conventional acylation procedures such as described e.g., in U.S. Pat. No. 5,025,021. Two preferred methods are as follows:
Method A--Compound (3) is refluxed with dibutyltin oxide in solvents (such as benzene, toluene, xylene, methanol or ethanol and the like) to form a homogenous solution. The stannylene intermediate is then reacted at 0°-50° C. in the presence of a base (such as triethylamine, pyridine, 4-dimethylaminopyridine, 1,8-diazabicyclo[5,4,0]undec-7-ene or diisopropylethylamine) and an acylating agent (such as acetyl chloride, benzoyl chloride, pivaloyl chloride, chloroacetyl chloride, acetic anhydride, isobutyric anhydride, methyl chloroformate, ethyl chloroformate, isobutylchlorofomate, phenyl chloroformate, benzyl chloroformate and the like) to provide selective protection at C-2 and give the novel intermediate (4).
Method B--A solution of compound (3) and tetrabutylammonium iodide in a chlorinated solvent such as methylene chloride, 1,2-dichloroethane or carbon tetrachloride is reacted with an acylating agent, e.g., benzoyl chloride, under basic conditions, e.g., with potassium carbonate, sodium carbonate or cesium carbonate to provide 2-O-acyl protection selectively at C-2 and give the novel intermediate (4).
Protection of the hydroxyl group at C-3 in step (d) can be carried out by forming an ether (e.g., methoxymethyl, metylthiomethyl, benzyl, benzyloxymethyl, 2,2,2-trichloroethoxymethyl, 2-methoxyethoxymethyl (MEM), 2-(trimethylsilyl)ethoxymethyl (SEM), triethylsilyl, tert-butyldimethylsilyl (TBDMS), tert-butyldiphenylsilyl, triisopropylsilyl, isopropyldimethylsilyl, methyldiisopropylsilyl or methyldi-tert-butylsilyl using conventional hydroxyl protection procedures (see, e.g., Green, T. W., Protective Groups in Organic Synthesis, Wiley, New York, 1981, 2d ed., 1991). Thus the intermediate compound (4) can be reacted with a protecting agent, e.g., 2-methoxy-ethoxymethyl chloride, 2-(trimethylsilyl)ethoxymethyl chloride, tert-butyldimethylsilyl trifluoromethnesulfonate or triisopropylsilyl trifluoromethnesulfonate to give the novel fully protected intermediate (5). This ether formation is preferably carried out in the presence of a non-polar, aprotic solvent (e.g., diethyl ether, tetrahydrofuran, dioxane, dimethoxyethane, dibutylether, tert-butyl methyl ether, methylene chloride, chloroform or carbon tetrachloride) using a base (such as triethylamine, pyridine, 4-dimethylaminopyridine, 1,8-diazabicyclo[5,4,0]undec-7-ene or diisopropylethylamine) at temperature of 0°-50° C.
Selective removal of the protecting group (ester or carbonate) at C-2 in step (e) can be carried out by reaction of the intermediate (5) with tetrabutylammonium hydroxide in aqueous dioxane or with other bases, e.g., aqueous sodium hydroxide, aqueous potassium hydroxide, aqueous potassium carbonate, aqueous lithium hydroxide, aqueous lithium carbonate, ammonium hydroxide or aqueous methylamine (with or without the presence of organic solvents such as methanol, ethanol or dioxane) to give the novel intermediate (6). The acetate group at C-2 can also be removed by reaction with potassium cyanide or sodium cyanide or by enzymatic reaction with lipases. Various of the carbonates at C-2 can also be removed by special conditions. For example, 2,2,2-trichloroethyl carbonate can be cleaved by treatment with zinc in methanol.
Since the rest of the molecule is fully protected, the oxidation of the secondary alcohol in (6) can be successfully carried out in step (f) by reaction with a variety of oxidizing agents [see, e.g., March, J. in Advanced Organic Chemistry, Wiley, New York, 1985; House, H. O. in Modern Synthetic Reactions, Benzamin Publishing Co., Massachusetts, 1972; Augustine, R. L. in Oxidations--Techniques and Applications in Organic Synthesis, Dekker, New York, 1969; W. P. Griffith and S. M. Levy, Aldrichchimica Acta 23, 13 (1990); R. M. Moriarty and O. Prakash, J. Org. Chem. 50, 151, (1985); A. Mancuso, D. Swern, Synthesis 165, (1981); S. Czernecki, C. Georgoulus, C. L. Stevens and K. Vijayakantam, Tetrahedron Lett. 26, 1699 (1985); J. Herscovici, M. J. Egra and K. Antonakis, J. Chem. Soc. Perkin Trans 1, 1967 (1982); E. J. Corey, E. Barrette and P. Magriotis, Tetrahedron Lett. 26, 5855 (1985); and H. Tomioka, K. Oshima and H. Nozaki, Tetrahedron Lett. 23, 539 (1982)]. Illustrative of the reagents suitable for oxidation of the C-2 hydroxyl in compound (6) are pyridinium chlorochromate (with or without additives such as sodium acetate, celite, alumina or molecular sieves), pyridinium dichromate, chromium trioxide/pyridine, 2,22'-bipyridinium chlorochromate, cyclic chromate ester [E. J. Corey, E. Barrette and P. Magriotis, Tetrahedron Lett. 26, 5855 (1985)], RuCl 2 (PPh 3 )3-tert-BuOOH, silver carbonate on celite, cerium (IV) ammonium nitrate (with or without sodium bromate), tetra-n-propylammonium perruthenate and activated dimethyl sulfoxide reagents (using DMSO and one of the electrophilic reagents such as acetic anhydride, trifluoroacetic anhydride [TFAA], oxalyl chloride, trifluorosulfonic anhydride or dicyclohexylcarbodiimide). Formation of the novel carbonyl compound (7) is preferentially carried out by oxidation of the hydroxyl group at C-2 in (6) with trifluoroacetic anhydride in dimethylsulfoxide (DMSO) using methylene chloride as solvent at -70° to 0° C.
The introduction of alkyl (C 1 -C 4 ), vinyl, alkynyl, aryl, aralkyl, and other R 4 groups at C-2 in compound (8) in step (g) can be achieved by stereoselective addition of organometallic reagents (R 4 M) to the 2-keto derivative (7) using conventional procedures (see, e.g., E. C. Ashby and J. T. Laemmle, Chemical Reviews, 75, 521 (1975); K. Maruoka, Y. Araki, and H. Yamamoto, Tetrahedron Lett. 29, 3101 (1988); and K. Maruoka, T. Itoh, and H. Yamamoto, J. Am. Chem. Soc 107, 4576 (1985)]. For example, 2-substituted tertiary carbinol derivatives (8) can be prepared by reaction of carbonyl compound (7) with Grignard reagents (e.g., methylmagnesium chloride, methylmagnesium bromide, ethylmagnesium bromide, isobutylmagnesium bromide, phenylmagnesium bromide, vinylmagnesium bromide or allylmagnesium bromide) in aprotic, non-polar solvent (e.g., diethyl ether, tetrahydrofuran, dioxane, dimethoxyethane, dibutylether, tert-butyl methyl ether or benzene) at -70° to 20° C. Other organometallic reagents such as methyl lithium, lithium acetylide, sodium acetylide, ethylenediamine complex, dimethyl magnesium, trimethyl aluminum, organozinc and organocadmium reagents obtained by addition of Grignard reagents (R 4 MgCl) with zinc and cadmium halides, ate complexes such as MeLi--Me 2 CuLi, LiMg(CH 3 ) 2 , LiAl(i-C 4 H 9 ) 3 CH 3 and LiAi(CH 3 ) 4 , can also be used to give the addition product (8).
The protecting group at C-3 in compound (8) is then removed in step (h) by appropriate selection of reagents to give the novel compound (9). For example, trialkylsilyl ethers and SEM ether in (8) can be removed by reagents carrying a fluoride source, such as tetrabutylammmonium fluoride, CsF, terabutylammonium chloride/KF, LiBF 4 or Ph 3 C + BF 4 - or Pyridine+HF to give (9). Methylthiomethyl ether can preferably be cleaved with mercuric chloride or silver nitrate. Similarly, 2,2,2-trichloromethoxymethyl ether can be cleaved by heating with Zn--Cu or Zn--Ag in methanol. Benzyl, substituted benzyl or benzyloxymethyl ethers can preferably be removed by catalytic hydrogenation procedures (using H 2 , Pd/C in solvents such as ethanol, methanol, isopropanol and tetrahydrofuran). This catalytic hydrogenation procedure to remove the benzyl ether is further useful because it simultaneously removes the N-protecting carbobenzoxy group from the compound (8) (W=OCH 2 Ph) and yields the novel intermediate (10) directly. If the hydroxyl group at C-3 is protected as methoxymethyl or 2-methoxyethoxyethyl ether, it can preferably be removed by aqueous acid (80% AcOH) or Lewis acid catalyzed cleavage (using ZnBr 2 , TiC 14 or HBF 4 ) after the carbamate hydrolysis (of N-1) or the reduction (of amide at N-1 to the corresponding tertiary amine) of compound (8).
The nitrogen protecting carbamate group in compound (9) can be easily removed in step (i) by base hydrolysis at temperature of 40° to 100° C. to give the novel compound (10). Illustrative bases suitable for this reaction are aqueous sodium hydroxide, lithium hydroxide or potassium hydroxide with or without the presence of organic solvents such as methanol, ethanol, ethylene glycol and dioxane. The carbamates can also be cleaved by other reagents such as sulfur nucleophiles (e.g., sodium thiomethoxide and lithium thiopropoxide) or iodotrimethylsilane. Benzyl or substituted benzyl carbamates can be removed by base hydrolysis as mentioned above or by catalytic hydrogenation procedures, e.g. H 2 and Pd/C or H 2 and Pd black.
The acetal or ketal group from the intermediate (10) can be removed in step (j) to give the novel intermediate (11) by using the following conditions elaborated for the individual group. For example, the cleavage of benzylidene group in (10) can preferably be carried out by using transfer hydrogenation in the presence of hydrogen donors such as cyclohexene or 1,4-cyclohexadiene. Thus, the benzylidene intermediate (10) is refluxed with Pd(OH) 2 in ethanol and cyclohexene to give the novel intermediate (11). The benzylidine group in (10) can similarly be removed by using metals (such as Li, Na or K) and liquid ammonia at -70° to -30° C. to give (11). The benzylidene acetal can also be cleaved using N-bromosuccinimide and BaCO 3 (or CaCO 3 ) in carbon tetrachloride or by electrochemical reduction. 2,2,2-Trichloroethylidine acetal is preferably cleaved by catalytic reduction (H 2 , Raney Ni) using aqueous sodium hydroxide and ethanol. Alternately, the intermediate (9) (R 1 =Ph, X=H, W=OCH 2 Ph) can be directly converted to (11) using either transfer hydrogenation [Pd(OH) 2 , cyclohexene] or Na/ammonia reduction. Similarly, the preferred intermediate (25) (in generic formula 8, R 3 =CH 2 Ph, R 1 =Ph, X=H, W=OCH 2 Ph) can also be converted to (11) in one step sequence using transfer hydrogenation or metal/ammonia reduction. ##STR3##
N-Alkylation of intermediate (11) can be carried out in step (k) by reductive alkylation procedures using NaCNBH 3 , NaBH 4 , and alkylaldehyde or by catalytic hydrogenation procedures such as described, e.g., in U.S. Pat. Nos. 4,182,763; 4,639,436; 5,003,072; and 5,003,638. For example, the N-alkylation can be carried out by reacting intermediate (11) with an appropriate alkylaldehyde in the presence of a hydrogen donor reducing agent, e.g., catalytically activated hydrogen. Hydrogenation in the presence of a noble metal catalyst, e.g., palladium, at elevated pressure and temperature in methanol solvent medium is suitable. Appropriate alkylaldehydes for preparing the corresponding N-alkyl derivative compounds (12) are, e.g., n-propanal, n-butanal, n-pentanal, n-hexanal, n-heptanal and n-octanal. Thus, reaction of an aldehyde having an alkyl moiety corresponding to the desired R in Formula I with Pd on carbon in aqueous ethanol and THF is suitable procedure. Preferred aldehydes for this reaction are, e.g., butyraldehyde, 3-phenylpropionaldehyde and 2-ethylbutyraldehyde to prepare novel antiviral compounds (XVIA), (XVIB) and (XVIC), respectively.
Alternatively, N-alkylation can be achieved by reacting intermediate (11) with alkylhalide such as benzyl bromide, bromobutane, bromohexane, iodomethane and the like in the presence of a base such as triethylamine, pyridine and diisopropylethylamine. Suitable solvents for the reaction are, e.g., DMF, dimethylacetamide, dimethylsulfoxide and pyridine.
When the nitrogen in DNJ (1) is acylated as an amide [intermediate (2), W=alkyl, aralkyl], the sequence to target 2-substituted tertiary carbinol derivatives proceeds as shown in Reaction Scheme A-B until the isolation of intermediate (9) ( W=alkyl, aralkyl). The sequence is then modified as illustrated in Reaction Scheme C. ##STR4##
The acetal or ketal group from compound (9) is first removed following the conditions illustrated for the synthesis of compound (11). The amide in the compound (14) so obtained is then reduced to alkyl derivative (12A, R 6 =CH 2 R) using reagents such as lithium aluminum hydride or borane-dimethyl sulfide complex. The novel intermediate (14) can also be prepared from the 2-alkyl carbinol derivative (11) by direct acylation using acyl halide (e.g., acetyl chloride, propionyl bromide, butyryl chloride or benzoyl chloride or anhydrides, e.g., acetic anhydride, propionic anhydride or butyric anhydride). The reaction of compound (11) with acyl halides is preferentially carried out in the presence of non-polar, aprotic solvents such as ethers, e.g., diethyl ether, tetrahydrofuran, dioxane, dimethoxyethane, dibutylether, tert-butyl methyl ether, or chlorinated solvents e.g., methylene chloride, chloroform and carbon tetrachloride, or hydrocarbon solvents, e.g., benzene and toluene. However, the reaction of (11) with anhydrides is preferentially carried out by dissolving in one or more of polar, protic solvents such as water, methanol or ethanol and in the presence of base, e.g., potassium carbonate, lithium carbonate, sodium carbonate, cesium carbonate, triethylamine, pyridine, 4-dimethylaminopyridine, diisopropylethylamine or 1,8-diazabicyclo[5,4,0]undec-7-ene]. Alternately, the compound (9) is reduced first (preferably with borane-dimethyl sulfide complex) to give the intermediate (15) which is then subjected to deacetalization/deketalization as illustrated above to give the compound (12A).
The compound (12) in Reaction Scheme A-B can be O-acylated (partially or fully) to give the novel compound (13) using conventional acylation procedures for acylation well known to those skilled in the art. Illustrative suitable general procedures for acylation of hydroxyl groups are described in U.S. Pat. No. 5,003,072; March, J. in Advanced Organic Chemistry, Wiley, New York, 1985; Green, T. W., Protective Groups in Organic Synthesis, Wiley, New York, 1981, 2d ed., 1991. For example, the compound (12) can be O-acylated to form ester or carbonate using a variety of reagents such as acyl halides, e.g., acetyl chloride and propionyl bromide, pivaloyl chloride, benzoyl chloride and butyryl chloride, or anhydrides, e.g., acetic anhydride, propionic anhydride and butyric anhydride, or chloroformates, e.g., methyl chloroformate, ethyl chloroformate, vinyl chloroformate, phenyl chloroformate and benzyl chloroformate. The reaction of compound (12) with the acylating agent is preferentially carried out in the presence of a base (such as triethylamine, pyridine, 4-dimethylaminopyridine, diisopropylethylamine or 1,8-diazabicyclo[5,4,0]undec-7-ene]. The reaction can be carried out using the base as a solvent or having additional co-solvent, e.g., diethyl ether, tetrahydrofuran, dioxane, dimethoxyethane, dibutylether, tert-butyl methyl ether, methylene chloride, chloroform, carbon tetrachloride, benzene or toluene. This reaction is preferably be carried out at 20 to 90° C.
In the synthesis of preferred novel compounds of Formula I according to the steps of the general Reaction Scheme A-B, the preferred reaction conditions are set forth in the following Reaction Schemes D, E and F. Synthesis of the 2-keto DNJ analogs VIIA to VIID from the starting DNJ (I) in steps (a) through (f) is set forth in Reaction Scheme D. The stereoselective Grignard addition to the 2-keto DNJ analogs VIIA to VIID to produce the 2-substituted tertiary carbinol intermediates VIIIA to XIIB in step (g) is set forth in Reaction Scheme E. The synthesis of the 2-substituted tertiary carbinol derivatives of DNJ, compounds XVIA to XVIC, from the 2-substituted tertiary carbinol intermediate XIA in steps (h) to (k) is set forth in Reaction Scheme F. The compound XVIA is esterified to give the pro-drugs XVIIIA to XVIIIC. The intermediate XV is acylated to XVIIA and XVIIB which are reduced to novel antiviral compound 12A of Reaction Scheme C. ##STR5##
__________________________________________________________________________Scheme E: Nucleophilic Additions to 2-Ketone Diastereomeric Ratio Chem. YieldCompound (R.sub.3) Reagent R.sub.4 of products (A/B) (%)__________________________________________________________________________ ##STR6## MeMgX Me VIIIA/VIIIB = <15/85 VIIIB = 62% ##STR7## Me.sub.3 SiCH.sub.2 LiCeCl.sub.3 CH.sub.2 SiMe.sub.3 IXA/IXB = <10/90 IXB = 43% ##STR8## MeMgX Me XA/XB = 33/67 XA = 21% XB = 43% ##STR9## MeMgX Me XIA/XIB = 92/8 XIA = 68% XIB = 5.4%Me MeMgX Me XIIA/XIIB = 93/7 XIIA = 54% XIIB__________________________________________________________________________ = 4% ##STR10##
Compounds of the following two structures can be synthesized by following the sequence of reaction steps and using the reaction conditions shown in Reaction Scheme F: ##STR11##
In the above formulas, alkyl preferably is propyl as in compounds (XVIIA) and (XVIIB) of Reaction Scheme F; and acyl preferably is butyryl as in compounds (XVIIIA), (XVIIIB) and (XVIIIC) of Reaction Scheme F.
In accordance with another embodiment of the invention, formation of the 2-substituted tertiary carbinols from the 2-keto derivative (7) can be carried out by alternate methods that involve elaboration of an olefin or opening of an epoxide. This method is illustrated by the following Reaction Scheme G: ##STR12##
Reaction Scheme G comprises the following general reaction steps:
The ketone (7) is converted to novel olefinic compound (16). This conversion of compound (7) to the olefinic compound (16) can be achieved by a variety of methodologies such as by Wittig or modified Wittig olefination [see e.g., P. J. Murphy, J. Brennan, Chem. Soc Rev. 17, 1, (1988)], using Tebbe's reagent [F. N. Tebbe, G. W. Parshall and G. S. Reddy, J. Am. Chem. Soc. 100, 3611, (1978)] or other titanium based reagents [e.g., L. Clawson, S. L. Buchwald and R. H. Grubbs, Tetrahedron Lett. 25, 5733, (1984)] or zirconium promoted olefination [J. M. Tour, P. V. Bedworth and R. Wu, Tetrahedron Lett 30, 3927, (1989)].
Olefinic intermediate (16) is reacted with 3-chloroperbenzoic acid (MCPBA) in methylene chloride at room temperature to form the novel epoxide intermediate derivative (17). The epoxidation of the olefin can similarly be achieved by a number of other reagents such as dimethyldioxirane, peroxy acids [see, e.g., Rebeck et al. J. Org. Chem. 51, 1649 (1986)], Sharpless epoxidations using t-butylhydroperoxide [see, e.g., Katsuki and Sharpless, J. Am. Chem. Soc. 102, 5974 (1980); Ibid. Vol. 109, 5675 (1987); Wang and Zhou, Tetrahedron 43, 2935 (1987); Finn and Sharpless, J. Am. Chem. Soc. 113, 113 (1991)]; and sulfamyloxaziridines (Davis et al., Tetrahedron Lett. 27, 5079 (1986)].
The ketone (7) can also be converted to the epoxide directly by using dimethyloxosulfonium methylide or dimethylsulfonium methylide [see, e.g., E. J. Corey and M. Chaykovsky, J. Am. Chem. Soc. 87, 1353 (1965)].
Both the olefin (16) and the epoxide (17) are novel and useful intermediates for the synthesis of variety of 2-substituted tert-carbinol derivatives represented in Formula I. For example, olefin (16) on treatment with osmium tetroxide (Reaction Scheme G) gives the diol (18), and the primary alcohol in (18) is alkylated with base (e.g., triethylamine) and alkyl halide (C 1 -C 4 ) to give the useful intermediate (19). The useful epoxide intermediate (17) can be opened with a variety of nucleophiles (Y) such as hydride, azide, thioalkyl and thioaryl (SR'; R'=H, methyl, phenyl), and amine (NR'R'; R'=H, methyl) to give the intermediate (20). The 2-azidomethyl derivative of compound (19) (Y=N 3 ) can also be elaborated to 2-aminomethyl (Y=NH 2 ) and 2-alkylaminomethyl (Y=NR'R') derivatives. Both the intermediates (19 & 20) can then be elaborated to the fully deprotected compounds represented by structure (21) using the methodologies discussed in Reaction Scheme B for the synthesis of (12).
The preferred conditions used for the synthesis of olefin (16) and epoxide (17) are shown in Reaction Scheme H. ##STR13##
The ketone VIIC is reacted with trimethyl-silylmethyllithium to give the addition product IXB. The acetonitrile solution of compound IXB or XIX is refluxed with a fluoride source such as tetrabutylammonium fluoride to give the novel olefinic intermediate XXA. The hydroxyl group at C-3 in XXA is reprotected using trialkylsilyl (e.g., tert-butyldimethylsilyl) to give the novel olefin XXB. Epoxidation of the olefin (XXB) using 3-chloroperbenzoic acid gives the diastereomeric mixture of epoxides (XXI & XXII) in ratio of 20/80. The lithium aluminum hydride reduction of the epoxides XXI & XXII gives the 2-methyl-tert-carbinol derivatives XXIII & XXIV, respectively.
The intermediate (4) of Reaction Scheme A-B can also be used for the synthesis of 3-substituted ether (R 8 =C 1 -C 6 ) or 3-substituted tert-carbinol derivatives (R 7 =R 4 ) as shown in Reaction Scheme I. The intermediates VD and VID of Reaction Scheme D are useful substrates for the synthesis of compounds (5) and (22) shown in Reaction Scheme I. ##STR14##
In standard in vitro tests, the novel compounds of the invention were demonstrated to inhibit HIV-1. These tests involved plating of susceptible human host cells which are syncytium-sensitive with and without virus in microculture plates, adding various concentrations of the test compound, incubating the plates for 9 days (during which time infected, non-drug treated control cells are largely or totally destroyed by the virus), and then determining the number of remaining viable cells using a colorimetric endpoint.
Potential use against the AIDS virus also is shown by the inhibitory activity of these compounds against visna virus in a conventional plaque reduction assay. Visna virus, a lentivirus genetically very similar to the AIDS virus, is pathogenic for sheep and goats. See Sonigo et al., Cell 42, 369-382 (1985); Haase, Nature 322, 130-136 (1986). Inhibition of visna virus replication in vitro as a useful model for human immunodeficiency virus (HIV) and its inhibition by test compounds has been described by Frank et al., Antimicrobial Agents and Chemotherapy 31(9), 1369-1374 (1987).
DETAILED DESCRIPTION OF THE INVENTION
The following examples will further illustrate the invention although it will be understood that the invention is not limited to these specific examples or the details disclosed therein.
EXAMPLE 1
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-D-glucitol (II)
To a stirred solution of 1-deoxynojirimycin (100 g, 0.61 mol) in saturated aqueous sodium bicarbonate (1000 ml), benzyl chloroformate (95%, 121 g, 0.67 mol) was added dropwise at room temperature. After stirring at room temperature for 18 hr, the solution was extracted once with methylene chloride (300 ml) to remove any unreacted benzyl chloroformate. The aqueous layer was then extracted several times with ethyl acetate to give a total of 2.5-3 liters of the extract. The organic layer was then dried (Na 2 SO 4 ), filtered and concentrated to give a white solid (98.57 g, 54%), mp 101°-2° C., Anal. calcd. for C 14 H 19 NO 6 : C, 56.56, H, 6.44, N, 4.71. Found: C, 56.33, H, 6.38, N, 4.58. 1 H NMR (CD 3 OD) 7.2-7.4 (m, 5H), 5.15 (s, 2H), 4.23 (br m, 1H), 4.05 (br d., J=8 Hz, 1H), 3.87 (dd, J=6, 4 Hz, 1H), 3.78-3.85 (m, 2H), 3.70-3.78 (m, 2H), 3.45 (br d, J=8 Hz, 1H).
EXAMPLE 2
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-D-glucitol (III)
A mixture of (II) (98.5 g, 0.33 mol) , benzaldehyde dimethyl acetal (65.5 g, 0.43 mol) and p-toluenesulfonic acid (1 g) in a round bottom flask was dissolved in dimethlformamide (400 ml). The flask was connected to a water aspirator and the reaction was heated to 60°-65° C. for 4 hr. The reaction mixture was cooled to room temperature and poured into stirred ice-water (1200 ml) containing sodium bicarbonate (14 g). The white solid formed was filtered, washed with cold water and dried. Recrystallization using hexane/ethyl acetate gave III (96.2 g, 54%) as pure white solid, mp 147°-48° C., Anal. calcd. for C 21 H 23 NO 6: C, 65.44, H, 6.02, N, 3.63. Found: C, 65.15, H, 5.93, N, 3.49. 1 H NMR (CD 3 OD) 7.28-7.53 (m, 10H), 5.61 (s, 1H), 5.14 (s, 2H), 4.77 (dd, J =11, 4.6 Hz, 1H), 4.38 (t, J=11 Hz, 1H), 4.16 (dd, J =13.4, 4.2 Hz, 1H), 3.5-3.7 (complex m, 3H), 3.35 (ddd, J=11, 11, 4.6 Hz), 2.97 (dd, J=13.4, 9.3 Hz, 1H).
EXAMPLE 3
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O -(R-phenylmethylene)-D-glucitol, 2-benzoate (IV)
Method A (Using Di-n-butyltin oxide)
A suspension of III (25 g, 64.9 mmol), dibutyltin oxide (98%, 17 g, 66.9 mmol) in toluene (300 ml) was heated to reflux with azeotropic removal of water for 16 hr, whereupon a homogeneous solution resulted. The reaction solution was cooled to room temperature and triethylamine (10.9 ml, 77.5 mmol) and benzoyl chloride (7.7 ml, 67.5 mmol)were added. After stirring at room temperature for 24 hr, the reaction was diluted with aqueous solution of saturated sodium bicarbonate. The aqueous layer was extracted with ethyl acetate (3×800 ml). The combined organic extracts were washed with 1N hydrochloric acid, water and brine. The organic layer was dried (MgSO 4 ) and concentrated and the crude product was purified using column chromatography (silica gel, hexane/ethyl acetate 7/3) to give IV (21.52 g, 68%), DSC (mp) 120° C., Anal. calcd. for C 28 H 27 NO 7 : C, 68.70, H, 5.55, N, 2.86. Found: C, 68.17, H, 5.63, N, 2.75. 1 H NMR (CDCl 3 ) 7.96 (d, J=8 Hz, 2H), 7.52 (t, J=8 Hz, 1H), 7.48 (m, 2H), 7.36 (t, J=8 Hz, 2H), 7.30 (complex m, 8H), 5.51 (s, 1H), 5.07 (s, 2H), 5.05 (m, 1H), 4.82 (dd, J=11, 5 Hz, 1H), 4.1 (dd, J=11, 10 Hz, 1H), 4.04 (dd, J=14, 3 Hz, 1H), 3.88 (dd, J=8, 6 Hz, 1H), 3.73 (dd, J=10, 8 Hz, 1H), 3.65 (brs, 1H), 3.42 (td, J=10, 5 Hz, 1H), 3.38 (dd, J=14, 7 Hz, 1H).
Method B (Using Tetrabutylammonium iodide)
To a suspension of III (1 g, 2.6 mmol) in methylene chloride (20 ml), tetrabutylammonium iodide (960 mg, 2.6 mol) was added, whereupon a homogenous solution resulted. Anhydrous potassium carbonate (972 mg, 5.2 mmol) was added to the reaction and was followed by addition of benzoyl chloride (0.3 ml, 2.6 mmol). After stirring at room temperature for 48 hr, the reaction mixture was filtered and the residue was washed with more methylene chloride. The combined organic filterates were washed with water and dried (MgSO 4 ). After concentration, the crude (2.38 g) was chromatographed (silica gel, hexane/ethyl acetate 7/3) to give IV (810 mg, 64%) identical to the product of Method A.
EXAMPLE 4
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O -(R-phenylmethylene)-3-O-[{2-(methoxy)ethoxy}methyl]-D-glucitol, 2-benzoate (VA)
To a homogenous solution of IV (1 g, 2.04 mmol) in methylene chloride (20 ml), N,N-diisopropylethylamine (99%, 2 ml, 12.27 mmol) and 2-methoxyethoxymethyl chloride (1.4 ml, 12.27 mmol) were added. After stirring at room temperature for 24 hr, the reaction mixture was diluted with methylene chloride (700 ml) and washed with water and brine. After drying (MgSO 4 ) and filteration, the organic solvent was removed and the crude (1.47 g) chromatographed (silica gel, hexane/ethyl acetate 1/1 ) to give pure VA (1.15 g, 98%), DSC (Tap) 109° C., Anal. calcd. for C 32 H 35 NO 9 0.3H 2 O: C, 65.92, H, 6.15, N, 2.40. Found: C, 65.81, H, 6.09, N, 2.48.
EXAMPLE 5
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(trimethylsilyl)ethoxy]methyl]-D-glucitol, 2-benzoate (VB)
To a homogenous solution of IV (35 g, 0.07 mol) in methylene chloride (450 ml), N,N-diisopropylethylamine (99%, 100 ml, 0.57 mol) and 2-(trimethylsilyl)-ethoxymethyl chloride (74.2 ml, 0.42 mol) were added. After stirring at room temperature for 24 hr, the reaction mixture was diluted with methylene chloride (700 ml) and washed with water and brine. After drying (MgSO 4 ) and filteration, the organic solvent was removed to give VB (60.8 g) as thick orange liquid and was used in the next step without further purification. 1 H NMR (CDCl 3 ) 8.19 (d, J=8 Hz, 2H), 7.4-7.8 (complex band, 14H), 5.78 (s, 1H), 5.4 (m, 1H), 5.26 (s, 2H), 5.08 (m, 1H), 5.07 (s, 2H), 4.1-4.35 (complex band, 4H), 3.65-3.9 (complex band, 4H), 0.94 (m, 2H), 0.00 (s, 9H).
EXAMPLE 6
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-{(1,1-dimethylethyl)dimethylsilyl}]-D-glucitol, 2-benzoate (VC)
To a homogenous solution of IV (12 g, 24.5 mmol) in methylene chloride (200 ml), N,N-diisopropylethylamine (99%, 12.6 ml, 73.5 mmol) and tert-butyldimethylsilyl trifluoromethanesulfonate (11.3 ml, 49 mmol) were added. After stirring at room temperature for 2 hr, the reaction mixture was diluted with methylene chloride (700 ml) and washed with aqueous sodium bicarbonate, water and brine. After drying (MgSO 4 ) and filteration, the organic solvent was removed and the crude (19 g) chromatographed (silica gel, hexane/ethyl acetate 8/2 ) to give VC (14.3 g, 97%) as thick liquid. 1 H NMR (CDCl 3 ) 8.02 (d, J=8 Hz, 2H), 7.57 (t, J=8 Hz, 1H), 7.52 (m, 2H), 7.43 (t, J=8 Hz, 2H), 7.37 (m, 2H), 7.30 (m, 6H), 5.58 (s, 1H), 5.14 (ddd, J=7, 5, 3 Hz, 1H), 5.08 (s, 2H), 4.89 (dd, J=11, 5 Hz, 1H), 4.16 (dd, J=11, 10 Hz, 1H), 4.03 (dd, J=14, 3 Hz, 1H), 3.98 (dd, J=8, 5 Hz, 1H), 3.84 (dd, J=10, 8 Hz, 1H), 3.55 (td, J=10, 5 Hz, 1H), 3.55 (dd, J=14, 7 Hz, 1H), 0.79 (s, 9H), 0.02 (s, 3H), 00.0 (s, 3H).
EXAMPLE 7
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)-carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-methyl-D-glucitol, 2-benzoate (VD)
To a homogenous solution of IV (1.08 g, 1.82 mmol) in dimethylacetamide (20 ml) at 0° C., sodium hydride (182 mg, 60% dispersion in mineral oil, 4.55 mmol) was added. After stirring for 20 min, iodomethane (570 μl, 9.1 mmol) was injected in and the mixture was stirred for 4 hr. The reaction was quenched with drops of acetic acid and diluted with water (100 ml). The crude mixture was extracted with methylene chloride (2×300) and the organic layer was washed with brine. After drying (MgSO 4 ) and filtration, the organic solvent was removed and the crude (1.18 g) chromatographed (silica gel, hexane/ethyl acetate 1/1) to give VD (410 mg, 45%) as white solid, DSC (mp) 130° C., Anal. calcd. for C 29 H 29 NO 7 0.2H 2 O: C, 68.68, H, 5.84, N, 2.76 Found C, 68.60, H, 5.89, N, 2.72.
EXAMPLE 8
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(methoxy)ethoxy}methyl]-D-glucitol (VIA)
To a solution of VA (12.91 g, 22 mmol) in dioxane (400 ml) and tetrabutylammonium hydroxide (30 ml of 40% aqueous solution diluted to 200 ml) was added. After stirring at room temperature for 5 hr, the reaction was neutralized with 1N HCl and concentrated to remove dioxane. The reaction mixture was extracted with methylene chloride and the organic layer was washed with brine. After drying (MgSO 4 ) and filteration, the solvent was removed and the crude (17.7 g) was chromatographed (silica gel, hexane/ethyl acetate 1/1 ) to give pure VIA (28.2 g, 93%), DSC (mp) 101° C., Anal. calcd. for C 25 H 31 NO 8 : C, 63.41, H, 6.60, N, 2.96. Found: C, 63.65, H, 6.68, N, 2.95.
EXAMPLE 9
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(trimethylsilyl)ethoxy}methyl]-D-glucitol (VIB)
The crude VB (60 g) as obtained above was dissolved in dioxane (500 ml) and tetrabutylammonium hydroxide (150 ml of 40% aqueous solution diluted to 500 ml) was added. After stirring at room temperature for 72 hr, the reaction was neutralized with 1N HCl and concentrated to remove dioxane. The reaction mixture was extracted with methylene chloride (3×800 ml) and the organic layer was washed with brine. After drying (MgSO 4 ) and filteration, the solvent was removed and the crude (90 g) was chromatographed (silica gel, hexane/ethyl acetate 8/2) to give pure VIB (28.2 g, 82% based on 2 steps from IV), DSC (mp) 108° C.; Anal. calcd. for C 27 H 37 NO 7 Si: C, 62.89, H, 7.23, N, 2.72. Found: C, 62.50, H, 7.23, N, 2.65.
EXAMPLE 10
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-{(1,1-dimethylethyl)dimethylsilyl}]-D-glucitol (VIC)
The crude VC (660 mg, 1.02 mmol) as obtained above was dissolved in dioxane (20 ml) and tetrabutylammonium hydroxide (1.3 ml of 40% aqueous solution diluted to 10 ml) was added. After stirring at room temperature for 16 hr, the reaction was neutralized with 1N HCl and concentrated to remove dioxane. The reaction mixture was extracted with methylene chloride and the organic layer was washed with brine. After drying (MgSO 4 ) and filteration, the solvent was removed and the crude (560 mg) was chromatographed (silica gel, hexane/ethyl acetate 8/2 ) to give VC (160 mg, 31%) and VIC (130 mg, 26%). 1 H NMR (DMSO-D 6 ) 7.3-7.45 (complex band, 10H), 5.6 (s, 1H), 5.27 (d, J=5.2 Hz, 1H, exchanges with D 2 O), 5.07 (s, 2H), 4.61 (dd, J=11 & 4.3 Hz, 1H), 4.2 (t, J=10.5 Hz, 1H), 3.82 (dd, J=13.2 & 4 Hz, 1H), 3.64 (dd, J=10 & 8.5 Hz, 1H), 3.51 (dd, J=8.5 & 6.2 Hz, 1H), 3.41 (complex band, 1H), 3.31 (ddd, J=10.2, 10.2 & 4.5 Hz, 1H), 3.04 (dd, J=13.2 & 8.8 Hz, 1H), 0.78 (s, 9H), 0.00 (s, 6H).
EXAMPLE 11
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy) -carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-methyl-D-glucitol (VID)
To a solution of VD (360 mg, 0.72 mmol) in dioxane (10 ml), tetrabutylammonium hydroxide (1.4 ml of 40% aqueous solution diluted to 7 ml) was added. After stirring at room temperature for 16 hr, the reaction was neutralized with 1N HCl and concentrated to remove dioxane. The reaction mixture was extracted with methylene chloride and the organic layer was washed with aqueous sodium bicarbonate and brine. After drying (MgSO 4 ) and filtration, the solvent was removed and the crude (270 mg) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give VID (210 mg, 73%). 1 H NMR (CDCl 3 ) 7.47 (m, 2H), 7.27-7.39 (complex band, 8H), 5.54 (s, 1H), 5.12 (d, J=12 Hz, 1H), 5.07 (d, J=12 Hz, 1H), 4.82 (dd, J=12 & 5 Hz, 1H), 4.39 (t, J=10 Hz, 1H), 4.22 (dd, J=13 & 5 Hz, 1H), 3.71 (t, J=10 Hz, 1H), 3.62 (s, 3H), 3.60 (complex band, 1H), 3.31 (ddd, J=10, 10 & 5 Hz, 1H), 3.23 (t, J=9 Hz, 1H), 2.94 (broad s, 1H), 2.87 (dd, J=13 & 9 Hz, 1H).
EXAMPLE 12
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(methoxy)ethoxy}methyl]-L-sorbose (VIIA)
To a cold solution of dimethyl sulfoxide (2.55 ml, 35.5 mmol) in methylene chloride (40 ml) at -70° C., trifluoroacetic anhydride (3.8 ml, 26.62 mmol) in methylene chloride (40 ml) was added over 15-20 min. The reaction mixture was stirred for 10 min and then a solution of VIA (8.4 g, 17.74 mmol) in methylene chloride (200 ml) was added over 20 min. The reaction temperature was allowed to rise to -20° C. over 90 min and then stirred at -30° C. for additional 2 hr. Reaction mixture was recooled (-70° C.) and triethylamine (8 ml) was added over 10 min. After stirring at -70° C. for 1 hr, the cold bath was removed and the reaction was stirred for 2 hr. The reaction solution was diluted with methylene chloride and washed with water. After drying over MgSO 4 , the organic fractions were filtered and concentrated. The crude liquid (9.45 g) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give VIIA (7.5 g, 89%) as pure white solid, DSC (mp) 116° C.; Anal. calcd. for C 25 H 29 NO 8 .0.25 H 2 O: C, 63.08, H, 6.25, N, 2.94. Found: C, 63.03, H, 6.22, N, 2.90.
EXAMPLE 13
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O -(R-phenylmethylene)-3-O-[{2-(trimethylsilyl)ethoxy}methyl]-L-sorbose (VIIB)
To a cold solution of dimethyl sulfoxide (6.58 ml, 0.092 mol) in methylene chloride (30 ml) at -70° C., trifluoroacetic anhydride (10.1 ml, 0.071 mol) in methylene chloride (30 ml) was added over 15-20 min. The reaction mixture was stirred for 20 min and then a solution of VIB (22.75 g, 0.046 mol) in methylene chloride (200 ml) was added over 45 min. The reaction temperature was allowed to rise to -20° C. over 90 min and then stirred at -20° C. for an additional 4 hr. The reaction mixture was recooled (-70° C.) and triethylamine (20 ml) was added over 10 min. After stirring at -70° C. for 45 min, the cold bath was removed and the reaction was stirred for 1 hr. The reaction solution was diluted with methylene chloride and washed with water. After drying over MgSO 4 , the organic fractions were filtered and concentrated. The crude liquid (39 g) was chromatographed (silica gel, hexane/ethyl acetate 75/25) to give VIIB (22.1 g, 97%) as pure white solid, mp 112°-114° C.; Anal. calcd. for C 27 H 35 NO 7 Si.1H 2 O: C, 61.0, H, 7.01, N, 2.63. Found: C, 61.19, H, 7.01, N, 2.72.
EXAMPLE 14
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-[{(1,1-dimethylethyl)dimethylsilyl}]-L-sorbose (VIIC)
To a cold solution of dimethyl sulfoxide (0.37 ml, 5.21 mol) in methylene chloride (5 ml) at -70° C., trifluoroacetic anhydride (0.57 ml, 4.04 mmol) in methylene chloride (5 ml) was added over 10 min. The reaction mixture was stirred for 10 min and then a solution of VIC (1.3 g, 2.6 mmol) in methylene chloride (20 ml) was added over 15 min. The reaction temperature was allowed to rise to -30° C. over 4 hr and then stirred at -40° C. for additional 1 hr. Reaction mixture was recooled (-70° C.) and triethylamine (1 ml) was added over 10 min. After stirring at -70° C. for 1 hr, the cold bath was removed and the reaction was stirred for 1 hr. The reaction solution was diluted with methylene chloride and washed with water. After drying over MgSO 4 , the organic fractions were filtered and concentrated. The crude compound (1.48 g) was chromatographed (silica gel, hexane/ethyl acetate 8/2) to give VIIC (0.99 g, 76%). 1 H NMR (CDCl 3 ) 7.47 (m, 2H), 7.32 (m, 8H), 5.56 (s, 1H), 5.12 (d, J=12 Hz, 1H), 5.06 (d, J=12 Hz, 1H), 4.77 (dd, J=11, 5 Hz, 1H), 4.25 (d, J=10 Hz, 1H), 4.18 (d, J=18 Hz, 1H), 4.14 (dd, J=11, 10 Hz, 1H), 4.07 (d, J=18 Hz, 1H), 3.93 (t, J=10 Hz, 1H), 3.70 (td, =10, 5 Hz, 1H), 0.86 (s, 9H), 0.11 (s, 3H), 0.0 (s, 3H).
EXAMPLE 15
Preparation of 1,5-dideoxy-1,5-[{(phenylmethoxy)-carbonyl}imino]-4,6O -(R-phenylmethylene)-3-O-methyl-L-sorbose (VIID)
To a cold solution of dimethyl sulfoxide (75 μl, 1.06 mol) in methylene chloride (5 ml) at -70° C., trifluoroacetic anhydride (112 μl, 0.79 mmol) in methylene chloride (5 ml) was added over 5 min. The reaction mixture was stirred for 10 min and then a solution of VID (210 mg, 0.53 mmol) in methylene chloride (5 ml) was added over 10 min. The reaction temperature was allowed to rise to -30° C. over 3 hr and then stirred at -30° C. for an additional 4 hr. Reaction mixture was recooled (-70° C.) and triethylamine (0.4 ml) was added over 10 min. After stirring at -70° C. for 1 hr, the cold bath was removed and the reaction was stirred for 1 hr, the cold bath was removed and the reaction was stirred for 1 hr. The reaction solution was diluted with methylene chloride and washed with water. After drying over MgSO 4 , the organic fractions were filtered and concentrated. The crude compound (260 mg) was chromatographed (silica gel, hexane/ethyl acetate 6/4) to give VIID (190 mg, 91%). 1 H NMR (CDCl 3 ) 7.51 (m, 2H), 7.36 (m, 8H), 5.61 (s, 1H), 5.17 (d, J=12 Hz, 1H), 5.10 (d, J=12 Hz, 1H), 4.82 (dd, J=11, 5 Hz, 1H), 4.25 (d, J=16 Hz, 1H), 4.21 (dd, J=11, 10 Hz, 1H), 4.11 (d, J=16 Hz, 1H), 4.06 (t, J=10 Hz, 1H), 3.96 (d, J=10 Hz, 1H), 3.77 (td, =10, 5 Hz, 1H), 3.64 (s, 3H).
EXAMPLE 16
Preparation of 1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-[{(1,1-dimethylethyl)dimethylsilyl}]-D-mannitol (VIIIB)
To a cold solution of VIIC (620 mg, 1.25 mmol) in tetrahydrofuran (15 ml) at -70° C., methyl magnesium bromide (1.25 ml, 3M in Et 2 O, 3.75 mmol) was added over 10 min. The reaction mixture was allowed to warm to -30° C. over 3 hr. After stirring at -20° to -30° C. for 2 hr, the reaction was quenched by adding saturated aqueous ammonium chloride and extracted with ethyl acetate. The organic layer was washed with brine and dried (MgSO 4 ), filtered and concentrated. The crude product (600 mg) was chromatographed (silica gel, hexane/ethyl acetate 8/2) to give pure VIIlB (440 mg, 67%). 1 H NMR (CDCl 3 ) 7.49 (m, 2H), 7.39 (m, 8H), 5.54 (s,1H), 5.17 (d, J=12 Hz, 1H), 5.13 (d, J=12 HZ, 1H), 4.72 (dd, J=12, 5 Hz,1H), 4.66 (dd, J=12, 10 Hz, 1H), 4.28 (d, J=14 Hz,1H), 3.9 (dd, J=10, 8 Hz, 1H), 3.55 (d, J=8 Hz, 1H), 3.25 (td, J=10, 5 Hz, 1H), 2.83 (dd, J=14, 2 Hz, 1H), 2.73 (d, J=2 Hz, 1H), 1.24 (s, 3H), 0.87 (s, 9H), 0.05 (s, 3H), -0.05 (s,3H).
EXAMPLE 17
Synthesis of phenylmethyl 8β-[{(1,1-dimethylethyl)dimethylsilyl}oxy]hexahydro-7-hydroxy-2R,2.alpha.-phenyl-7-[(trimethylsilyl)methyl]-5H-4aα, 8aβ-1,3-dioxino[5,4-b]pyridine-5-carboxylate (IXB)
The cerium chloride (1.5 g, 6 mmol) was dried under vacuum (0.1 mm Hg) with stirring at 140° C. for 18 hr. After cooling to approx. 20° C., dry tetrahydrofuran (50 ml) was added and the mixture was stirred under argon for 2 hr. The reaction mixture was cooled to -78° C. and trimethylsilylmethyllithium (12 ml, 1M solution in pentane, 12 mmol) was added to the reaction flask over 10 min. After stirring for 1 hr, a solution of VIIC (1.35 g, 2.7 mmol) in THF (35 ml) was added over 20 min. The bath temperature was allowed to rise to -10° C. over 4 hrs and stirred at -10° C. for 18 hrs. The reaction mixture was quenched with ethylenediamine (1.5 ml), stirred for 40 min and then diluted with ethyl acetate. The organic layer was separated and washed with aqueous potassium carbonate and brine. After drying the organic layer over MgSO 4 , the solvent was removed and the crude product (1.82 g) chromatographed (silica gel, hexane/ethyl acetate 8/2) to give IXB (680 mg, 43%). 1 H NMR (CDCl 3 ) 7.25-7.57 (complex band, 10H), 5.52 (s, 1H), 5.14 (d, J=12 Hz, 1H), 5.10 (d, J=12 Hz, 1H), 4.69 (m, 2H), 4.42 (d, J=14 Hz, 1H), 3.85 (dd, J=10, 8 Hz, 1H), 3.48 (d, J=8 Hz, 1H), 3.24 (distorted q, J=9 Hz, 1H) , 2.73 (broad d, J=14 Hz, 1H), 2.65 (broad s, 1H), 1.4 (d, J=15 Hz, 1H), 0.86 (s, 9H), 0.62 (d, J=15 Hz, 1H), 0.06 (s, 9H), 0.04 (s, 3H), -0.07 (s, 3H).
EXAMPLE 18
Preparation of 1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(methoxy)ethoxy}methyl]-D-glucitol (XA) and1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(methoxy)ethoxy}methyl}-D mannitol XB
To a cold solution of VIIA (4.92 g, 10.43 mmol) in tetrahydrofuran (120 ml) at -70° C., methyl magnesium bromide (10.5 ml, 3M in Et 2 O, 31.3 mmol) was added over 10 min. The reaction mixture was stirred at -70° C. for 2 hr and then allowed to warm to -30° C. over 2 hr. After stirring at -30° C. for 4 hr, the reaction was quenched by adding saturated aqueous ammonium chloride (700 ml) and extracted with ethyl acetate. The organic layer was washed with brine and dried (MgSO 4 ), filtered and concentrated. The crude (5.4 g) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give XA (1.08 g, 21%) and XB (2.2 g, 43.3%). XA: mp 75°-76° C.; Anal calcd. for C 26 H 33 NO 8 : C, 64.05, H, 6.82, N, 2.87 Found C, 63.74, H, 6.92, N, 2.80; 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.37 (m, 8H), 5.53 (s,1H), 5.11 (d, J=12 Hz, 1H), 5.06 (d, J=12 Hz, 1H), 4.87 (d, J =5 Hz, 1H), 4.85 (d, J=5 Hz, 1H), 4.83 (dd, J=12, 5 Hz, 1H), 4.52 (dd, J=12, 11 Hz, 1H), 4.35 (broad s, 1H), 4.18 (d, J=14 Hz, 1H), 3.90 (m, 1H), 3.68 (m, 1H), 3.63 (dd, J=9.5, 9 Hz, 1H), 3.56 (d, J=9 Hz, 1H), 3.53 (m, 2H), 3.37 (s, 3H), 3.26 (ddd, J=11, 9.5, 5 Hz, 1H), 2.79 (d, J=14 Hz, 1H), 1.23 (s, 3H). XB: Anal calcd. for C 26 H 33 NO 8 0.8H 2 O: C, 62.21, H, 6.95, N, 2.79 Found C, 62.31, H, 6.71, N, 2.74; 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.37 (m, 8H), 5.54 (s,1H), 5.13 (d, J=12 Hz, 1H), 5.09 (d, J=12 Hz, 1H), 5.06 (d, J=7 Hz, 1H); 4.83 (d, J=7 Hz, 1H), 4.74 (dd, J=12, 5 Hz, 1H), 4.60 (dd, J=12, 10 Hz, 1H), 4.21 (d, J=14 Hz, 1H), 4.08 (dd, J=10, 9 Hz, 1H), 3.76 (m, 1H), 3.68 (m, 1H), 3.55 (d, J=9 Hz, 1H), 3.36 (m, 2H), 3.31 (s, 3H), 3.23 (ddd, J=11, 10, 5 Hz, 1H), 2.8 (d, J=14 Hz, 1H), 2.49 (broad s, 1H), 1.27 (s, 3H).
EXAMPLE 19
Preparation of 1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(trimethylsilyl)ethoxy}methyl]-D-glucitol (XIA) and 1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-[{2-(trimethylsilyl)ethoxy}methyl]-D-mannitol (XIB)
To a cold solution of VIIB (720 mg, 1.47 mmol) in tetrahydrofuran (25 ml) at -70° C., methyl magnesium bromide (1.5 ml, 3M in Et 2 O, 4.41 mmol) was added over 10 min. The reaction mixture was allowed to warm to -30° C. over 3 hr. After stirring at -20° to -30° C. for 4 hr, the reaction was quenched by adding saturated aqueous ammonium chloride and extracted with ethyl acetate (2×150 ml). The organic layer was washed with brine and dried (MgSO 4 ), filtered and concentrated. The crude (920 mg) was chromatographed (silica gel, hexane/ethyl acetate 75/25) to give pure XIA (530 mg, 68%) and XIB (42 mg, 5%). X1A: Anal calcd. for C 28 H 39 NO 7 Si.0.5H 2 O: C, 62.43, H, 7.48, N, 2.6 Found C, 62.34, H, 7.34, N, 2.56; 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.37 (m, 8H), 5.54 (s,1H), 5.10 (d, J=12 Hz, 1H), 5.05 (d, J=12 Hz, 1H), 4.88 (d, J =7 Hz, 1H), 4.82 (dd, J=11.5, 4 Hz, 1H), 4.68 (d, J=7 Hz, 1H), 4.52 (br.t, J=11.5, 11 Hz, 1H), 4.43 (s, 1H), 4.19 (d, J=14 Hz, 1H), 3.86 (m, 1H), 3.63 (dd, J =10, 9 Hz, 1H), 3.56 (m, 1H), 3.44 (d, J=9 Hz, 1H), 3.25 (td, J=10, 4 Hz, 1H), 2.77 (d, J=14 Hz, 1H), 1.21 (s, 3H). 0.94 (m, 2H), 0 (s, 9H). X1B: 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.37 (m, 8H), 5.57 (s,1H), 5.16 (d, J=12 Hz, 1H), 5.11 (d, J=12 Hz, 1H), 5.02 (d, J=7 Hz, 1H), 4.83 (d, J=7 Hz, 1H), 4.74 (dd, J=11.5, 4.7 Hz, 1H), 4.62 (br.t, J=11.5, 10.2 Hz, 1H), 4.24 (d, J=14 Hz, 1H), 4.10 (dd, J=9.9, 8.8 Hz, 1H), 3.76 (m, 1H), 3.56 (m, 1H), 3.54 (m, 1H), 3.25 (td, J=10, 4.7 Hz, 1H), 2.83 (dd, J=14, 1.9 Hz, 1H), 2.37 (d, J=1.9 Hz, 1H), 1.3 (s, 3H). 0.91 (m, 2H), 0 (s, 9H).
EXAMPLE 20
Preparation of 1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O -(R-phenylmethylene)-3-O-methyl-D-glucitol (XIIA) and 1,5-dideoxy-2-C-methyl -1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-3-O-methyl-D-mannitol (XIIB)
To a cold solution of VIID (193 mg, 0.5 mmol) in tetrahydrofuran (10 ml) at -70° C., methyl magnesium bromide (0.5 ml, 3M in Et 2 O, 1.5 mmol) was added over 10 min. The reaction mixture was allowed to warm to -30° C. over 2 hr. After stirring at -20° to -30° C. for 4 hr, the reaction was quenched by adding saturated aqueous ammonium chloride and extracted with ethyl acetate (50 ml). The organic layer was washed with brine and dried (MgSO 4 ), filtered and concentrated. The crude (190 mg) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give pure XIIA (111 mg, 54%) and XIIB (7.1 mg, 4%). XIIA. Anal calcd. for C 23 H 27 NO 6 .0.2H 2 O: C,66.24, H, 6.62, N, 3.32 Found C, 66.12, H, 7.17, N, 3.05; 1 H NMR (CDCl 3 ) 7.49 (m, 2H), 7.36 (m, 8H), 5.57 (s,1H), 5.12 (d, J=12 Hz, 1H), 5.07 (d, J=12 Hz, 1H), 4.84 (dd, J =12, 5 Hz, 1H), 4.50 (dd, J=12, 10 Hz, 1H), 4.10 (d, J=13 Hz, 1H), 3.69 (t, J=10 Hz, 1H), 3.66 (s, 3H), 3.31 (td, J=10, 5 Hz, 1H), 3.26 (d, J=10 Hz, 1H), 2.84 (d, J=13 Hz, 1H), 2.25 (s, 1H), 1.22 (s, 3H). XIIB. Anal calcd. for C 23 H 27 NO 6 .0: C,66.81, H, 6.58, N, 3.39 Found C, 66.91, H, 6.90, N, 2.94; 1 H NMR (CDCl 3 ) 7.25-7.5 (m, 10H), 5.60 (s,1H), 5.14 (d, J=12 Hz, 1H), 5.09 (d, J=12 Hz, 1H), 4.73 (dd, J=11, 5 Hz, 1H), 4.62 (dd, J=11, 10.6 Hz, 1H), 4.22 (d, J=14 Hz, 1H), 4.06 (dd, J=10, 8.7 Hz, 1H), 3.66 (s, 3H), 3.21 (td, J =10, 4.6 Hz, 1H), 3.08 (d, J=8.7 Hz, 1H), 2.79 (dd, J =14, 1.8 Hz, 1H), 2.36 (d, J=1.8 Hz, 1H), 1.26 (s, 3H).
EXAMPLE 21
Preparation of 1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-D-glucitol (XIII)
To a homogenous solution of XIA (7.8 g, 14.75 mmol) in tetrahydofuran (150 ml), tetrabutylammonium fluoride (88 ml, 1M solution in tetrahydofuran, 88 mmol) was added. After stirring at room temperature for 25 min, the solvent was removed and the residue dried under vacuum for 4 hr. The dried product was suspended in 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone (DMPU) (50 ml) and molecular sieves (4A°, pre-dried, 5 g) were added. The reaction mixture was heated at 80° C. for 18 hr, cooled to room temperature and diluted with Et 2 O (1000 ml). The ethereal layer was separated, washed with water, dried (MgSO 4 ) and concentrated. The crude product (13.6 g) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give XIII (3.83 g, 65%) as pure white solid, mp 104°-6° C.; Anal. calcd. for C 22 H 25 NO 6 0.3H 2 O: C, 65.27, H, 6.37, N, 3.46. Found: C, 65.22, H, 6.29, N, 3.42. 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.37 (m, 8H), 5.51 (s,1H), 5.11 (d, J=12 Hz, 1H), 5.06 (d, J=12 Hz, 1H), 4.81 (dd, J=12, 5 Hz, 1H), 4.44 (dd, J=12, 10 Hz, 1H), 4.06 (d, J=14 Hz, 1H), 3.59 (d, J=9 Hz, 1H), 3.51 (dd, J=10, 9 Hz, 1H), 3.23 (td, J=10, 5 Hz, 1H), 2.73 (d, J=14 Hz, 1H), 2.98 (broad s, 1H), 2.58 (broad s, 1H), 1.2 (s, 3H).
EXAMPLE 22
Preparation of 1,5-dideoxy-1,5-imino-2-C-methyl-4,6-O-(R-phenylmethylene)-D-glucitol (XIV)
To a solution of XIII (3 g, 7.5 mmol) in methanol (200 ml) in a Fischer-Porter bottle, 10% Pd on C (375 mg) was added. The bottle was sealed, purged with nitrogen, purged with hydrogen and then pressurized to 60 psi hydrogen pressure. After agitating at room temperature for 70 min, the reaction was vented to remove hydrogen. The catalyst was filtered and the residue washed with more methanol. The combined organic filterates were concentrated and the crude product was chromatographed (silica gel, methylene chloride/methanol/30% aqueous ammonium hydroxide 90/10/1) to give pure XIV (1.68 g, 84%) as white solid. Anal. calcd. for C 14 H 19 NO 4 0.25 H 2 O: C, 62.32, H, 7.28, N, 5.19. Found: C, 62.28, H, 7.44, N, 5.06.
EXAMPLE 23
Synthesis of 1,5-imino-1,5-dideoxy-2-C-methyl-D-glucitol (XV):
Method A (Using Transfer hydrogenation)
To a clear solution of XIV (550 mg, 2.07 mmol) in ethanol (20 ml) and cyclohexene (40 ml), 20% Pd(OH) 2 on C (500 mg) was added. After refluxing the mixture for 6 hr, more catalyst (300 mg) and cyclohexene (80 ml) were added. The mixture was refluxed for 18 hr and additional amounts of catalyst (200 mg) and cyclohexene (80 ml) were added. After refluxing for an additional 24 hrs, the reaction mixture was cooled and filtered. The residue was washed with methanol (300 ml) and the filterate was concentrated to give the residue (620 mg). The residue was subjected to chromatography (silica gel, methylene chloride/methanol/30% ammonium hydroxide 90/10/1 and then methylene chloride/methanol/30% ammonium hydroxide 50/50/2.5) and gave recovered starting material XIV (90 mg, 16%) and XV (285 mg, 73%) as pure white solid. DSC (mp) 214°-16° C. Anal. calcd. for C 7 H 15 NO 4 0.1 H 2 O: C, 46.97, H, 8.56, N, 7.82. Found: C, 46.87, H, 8.62, N, 7.79.
Method B fusing sodium/lig. ammonia)
The compound XIV (180 mg, 0.68 mmol) was dissolved in liquid ammonia (20 ml) at -70° C. and was reduced by adding small pieces of sodium metal. The reaction mixture was stirred for 20 mins at -60° C. The cold bath was removed and the excess ammonia was allowed to escape. The white residue was quenched with water and the solution was passed thru an ion-exchange column (Amberlite IRA 400, OH). The basic fractions were collected and concentrated. The crude product (190 mg) was purified by chromatographed as in Method A to give XV (55 mg, 45%) identical to the product of Method A.
EXAMPLE 24
Synthesis of 1,5-Butylimino-1,5-dideoxy-2-C-methyl-D-glucitol (XVIA)
To a solution of XV (170 mg, 0.96 mmol) and butyraldehyde (150 mg, 2.1 mmol) in methanol (12 ml), water (3ml) and tetrahydrofuran (6 ml) in a Fischer-Porter bottle, 5% Pd on C (35 mg) was added. The bottle was sealed, purged with nitrogen, purged with hydrogen and then pressurized to 5 psi hydrogen pressure. After agitating at room temperature for 70 hr, the reaction was vented to remove hydrogen. The catalyst was filtered and the residue washed with more methanol. The combined organic filterates were concentrated and the crude product (260 mg) was chromatographed (silica gel, methylene chloride/methanol/30% ammonium hydroxide 85/15/1.5) to give XVIA (188 mg, 84%). mp 68°-70° C., Anal. calcd. for C 11 H 23 NO 4 0.25 H 2 O: C, 55.56, H, 9.96, N, 5.89. Found: C, 55.58, H, 9.86, N, 5.79.
EXAMPLE 25
Synthesis of 1,5-(3-phenylpropylimino)-1,5-dideoxy-2-C-methyl-D-glucitol (XVIB)
The type reaction of Example 24 was repeated using XV (130 mg, 0.73 mmol) and 3-phenylpropionaldehyde (130 mg, 0.97 mmol), 5% Pd on C (30 mg) in methanol (12 ml), water (3 ml) and tetrahydrofuran (3 ml). The crude (220 mg) obtained after work up was purified on column (silica gel, methylene chloride/methanol/30% ammonium hydroxide 75/25/1) to give pure XVIB (140 mg, 65%), DSC (mp) 94° C., Anal. calcd. for C 16 H 25 NO 4 0.4H 2 O: C, 63.51, H, 8.59, N, 4.63. Found: C, 63.56, H, 8.36, N, 4.66.
EXAMPLE 26
Synthesis of 1,5-(2-ethylbutylimino)-1,5-dideoxy-2-C-methyl-D-glucitol (XVIC)
The type reaction of Example 24 was repeated using XV (130 mg, 0.73 mmol) and 2-ethylbutyraldehyde (130 mg, 1.3 mmol), 5% Pd on C (30 mg) in methanol (12 ml), water (3 ml) and tetrahydrofuran (3 ml). The crude product (220 mg) obtained after work up was chromatographically purified on a column (silica gel, methylene chloride/methanol/30% ammonium hydroxide 75/25/1) to give pure XVIC (70 mg, 37%), mp 78°-80° C., Anal. calcd. for C 13 H 27 NO 4 0.3H 2 O: C, 58.53, H, 10.43, N, 5.25. Found: C, 58.64, H, 10.15, N, 5.35.
EXAMPLE 27
Synthesis of 1,5-dideoxy-2-C-methyl-1,5-[(1-oxabutyl)imino]-D-glucitol, 6-butanoate (XVIIA)
A solution of XV (35 mg, 0.2 mmol) in butyric anhydride (3 ml) was stirred at room temperature. After 28 hr, the solvent was removed under argon at room temperature and the crude liquid was passed through a short column (silica gel, methylene chloride/methanol/ammonium hydroxide 90/10/1) to give XVIIA (29 mg, 46%), 1 H NMR (CD 3 OD) 5.08 (broad dd, J=10, 4 Hz, 1H), 4.81 (dd, J=12, 10 Hz, 1H), 4.64 (dd, J=12, 10 Hz, 1H), 4.36 (broad D, J=10 Hz, 1H), 4.29 (d, J=14 Hz, 1H), 4.12 (dd, J=12, 4 Hz, 1H), 4.06 (dd, J=12, 4 Hz, 1H), 3.82 (dd, J=4, 2 Hz, 2H), 3.47 (s, 2H), 3.46 (d, J=4 Hz, 1H), 3.45 (d, J=4 Hz, 1H), 2.94 (d, J=14 Hz, 1H), 2.56 (ddd, J=15, 8, 6 Hz, 1H), 2.43 (t, J=7 Hz, 1H), 2.36 (ddd, J=15, 8, 7 Hz, 1H), 2.28 (t, J=7 Hz, 2H) , 2.24 (t, J=7 Hz, 2H) , 1.53-1.75 (complex band, 8H), 1.20 (s, 6H), 0.97 (t, J=7 Hz, 3H), 0.92 (t, J=7 Hz, 3H). It might be noted that the integrals to NMR signals are assigned assuming that 1H=one proton signal of one rotamer.
EXAMPLE 28
Synthesis of 1,5-dideoxy-2-C-methyl- 1,5-[(1-oxabutyl)imino]-D-glucitol (XVIIB)
To a solution of XV (22 mg, 0.12 mmol) in methanol (0.5 ml), butyric anhydride (0.5 ml) was added and the reaction mixture was stirred at room temperature. After 3 hr, the solvent was removed under argon at room temperature and the crude liquid was passed through a short column (silica gel, methylene chloride/methanol/ammonium hydroxide 90/10/1) to give XVIIA (6.9 mg, 10%) and XVIIB (27 mg, 88%). 1 H NMR (CD 3 OD) 4.32 (d, J=14 Hz, 1H), 4.17 (broad dd, J=7, 1.5 Hz, 1H), 4.02 (dd, J=12, 9.5 Hz, 1H), 3.89 (broad t, J=2.4 Hz, 1H), 3.81 (dd, J=12, 7.4 Hz, 1H), 3.79 (m, 1H), 3.78 (m, 1H), 3.76 (dd, J=12, 6.1 Hz, 1H), 3.63 (dd, J=12, 4.3 Hz, 1H), 3.51 (d, J=14 Hz, 1H), 3.45 (m, 2H), 3.40 (d, J=14 Hz, 1H), 2.92 (d, J=14 Hz, 1H), 2.58 (m, 1H), 2.46 (m, 1H), 2.46 (t, J=7.3 Hz, 2H), 1.67 (m, 4H), 1.18 (s, 6H), 0.97 (t, J=7 Hz, 3H), 0.96 (t, J=7 Hz, 3H). It might be noted that the integrals to NMR signals are assigned assuming that 1H=one proton signal of one rotamer. MS (EI) 247 (M+)
EXAMPLE 29
Synthesis of 1,5-(butylimino)-1,5-dideoxy-2-C-methyl-D-glucitol, (3 and/or 4), 6-perbutanoate (XVIIIA, XVIIIB & XBIIIC)
To a suspension of XVIA (35 mg, 0.15 mmol) in pyridine (3 ml), butyric anhydride (145 μl, 0.89 mmol) was added and the mixture was stirred for 7 days. The solvent was removed under argon at room temperature and the crude (62 mg) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give XVIIIA (6 mg, 9%), XVIIIB (16 mg, 29%) & XVIIIC (9 mg, 16%). XVIIIA 1 H NMR (CDCl 3 ) 4.99 (t, J=6 Hz, 1H), 4.80 (d, J=6.4 Hz, 1H), 4.25 (dd, J =12, 5 Hz, 1H), 4.21 (d, J=12, 5 Hz, 1H), 3.07 (broad s, 1H), 2.83 (d, J=12 Hz, 1H), 2.82 (m, 1H), 2.64 (m, 1H) , 2.54 (m, 1H) , 2.2-2.39 (complex band, 7H) , 1.53-1.7 (complex band, 6H), 1.43 (m, 2H), 1.3 (m, 2H), 1.22 (s, 3H), 0.88-0.97 (complex band, 12H); MS (Cl, NH 3 ) 444 (M+1). XVIIIB 1 H NMR (CDCl 3 ) 4.69 (d, J=7.7 Hz, 1H), 4.43 (dd, J=12.2, 3.8 Hz, 1H), 4.35 (dd, J=12.2, 3.8 Hz, 1H), 3.56 (broad t, J=7.4 Hz, 1H), 2.78 (d, J=11.7 Hz, 1H), 2.71 (m, 1H), 2.58 (td, J=7.4, 3.8 Hz, 1H), 2.49 (m, 1H), 2.28-2.4 (complex band, 4H), 1.61-1.73 (complex band, 4H), 1.43 (m, 2H), 1.3 (m, 2H), 1.22 (s, 3H), 0.88-1 (complex band 9H); MS (Cl, NH 3 ) 374 (M+1) XVIIIC 1 H NMR (CDCl 3 ) 4.84 (t, J=7 Hz, 1H), 4.34 (dd, J=12.2, 4 Hz, 1H), 4.20 (dd, J=12.2, 3.9 Hz, 1H), 3.48 (dd, J=7.2, 5.3 Hz, 1H), 2.80 (d, J=11.5 Hz, 1H), 2.71 (m, 1H), 2.68 (m, 1H), 2.53 (m, 1H), 2.25-2.38 (complex band 4H), 1.62-1.71 (complex band, 4H), 1.42 (m, 2H), 1.32 (m, 2H), 1.28 (s, 3H), 0.88-1 (complex band, 9H); MS (Cl, NH 3 ) 374 (M+1).
EXAMPLE 30
Synthesis of phenylmethyl hexahydro-Sβ-hydroxy-7-hydroxy-2R,2α-phenyl -7-[(trimethylsilyl)methyl]-5H-4aα, 8aβ-1,3-dioxino[5,4-b]pyridine-5-carboxylate (XIX)
To a solution of IXB (60 mg, 0.1 mmol) in THF (4 ml), tetrabutylammonium fluoride (0.3 ml, 1M solution in THF, 0.3 mmol) was added and the contents were stirred at 20° C. for 18 hr. The reaction mixture was diluted with ethyl acetate and the organic layer was washed with water and brine. After drying (MgSO 4 ), the solvent was removed and the crude product (58 mg) was chromatographed (silica gel, hexane/ethyl acetate 7/3) to give XIX (40 mg, 85%). 1 H NMR (CDCl 3 ) 7.49 (m, 2H), 7.37 (m, 8H), 5.57 (s, 1H), 5.14 (d, J=12 Hz, 1H), 5.10 (d, J=12 Hz, 1H), 4.76 (dd, J=12, 5 Hz, 1H), 4.61 (dd, J=12, 10 Hz, 1H), 4.38 (d, J=14 Hz, 1H), 3.90 (dd, J=10, 8 Hz, 1H), 3.46 (dd, J=8, 2.5 Hz, 1H), 3.22 (td, J=10, 5 Hz, 1H), 2.74 (dd, J=14, 2 Hz, 1H) , 2.63 (d, J=2.5 Hz, 1H), 2.29 (d, J=2 Hz, 1H), 1.33 (d, J=15 Hz, 1H), 0.80 (d, J=15 Hz, 1H), 0.07 (s, 9H).
EXAMPLE 31
Synthesis of phenylmethyl-hexahydro-Sβ-hydroxy-7-methylene-2R,2α-phenyl-5H-4aα, 8aβ-1,3-dioxino[5,4-b]pyridine-5-carboxylate (XXA)
To a solution of XIX (40 mg, 0.084 mmol) in acetonitrile (2 ml), tetrabutylammonium fluoride (0.5 ml, 1M solution in THF, 0.5 mmol) was added and the contents were refluxed for 18 hr. After cooling to room temperature, the reaction mixture was diluted with ethyl acetate and the organic layer was washed with water and brine. After drying (MgSO 4 ), the solvent was removed and the crude product (32 mg) was chromatographed (silica gel, hexane/ethyl acetate 7/3) to give XXA (21 mg, 65%). 1 H NMR (CDCl 3 ) 7.51 (m, 2H), 7.37 (complex band, 8H), 5.58 (s, 1H), 5.35 (broad s, 1H), 5.13 (broad s, 1H), 5.12 (s, 2H), 4.81 (dd, J=12, 5 Hz, 1H), 4.61 (d, J=15 Hz, 1H), 4.44 (dd, J=12, 10 Hz, 1H), 4.27 (broad d, J =9 Hz, 1H), 3.63 (dd, J=10, 9 Hz, 1H), 3.55 (d, J=15 Hz, 1H), 3.42 (td, J=10, 5 Hz, 1H), 2.68 (broad s,1H).
EXAMPLE 32
Synthesis of phenylmethyl-hexahydro-8β-hydroxy-7-methylene-2R,2α-phenyl -5H-4aα, 8aβ-1,3-dioxino[5,4-b]pyridine-5-carboxylate (XXA)
To a solution of IXB (600 mg, 1.03 mmol) in acetonitrile (5 ml), tetrabutylammonium fluoride (7 ml, 1M solution in THF, 7 mmol) was added and the contents were refluxed for 18 hr. After cooling to room temperature, the reaction mixture was diluted with ethyl acetate and the organic layer was washed with water and brine. After drying (MgSO 4 ), the solvent was removed and the crude product (480 mg) was chromatographed (silica gel, hexane/ethyl acetate 7/3) to give XXA (112 mg, 29%) identical to the product of Example 31.
EXAMPLE 33
Synthesis of phenylmethyl 8β-[{(1,1-dimethylethyl)dimethylsilyl}oxy]hexahydro-7-methylene-2R,2.alpha.-phenyl-5H-4aα, 8aβ-1,3-dioxino[5,4-b]pyridine -5-carboxylate (XXB)
To a homogenous solution of XXA (100 mg, 0.26 mmol) in methylene chloride (5 ml), N,N-diisopropylethylamine (99%, 140 μl, 0.78 mmol) and tert-butyldimethylsilyl trifluoromethanesulfonate (120 μl, 0.52 mmol) were added. After stirring at room temperature for 2 hr, the reaction mixture was diluted with methylene chloride (700 ml) and washed with aqueous sodium bicarbonate, water and brine. After drying (MgSO 4 ) and filteration, the organic solvent was removed to give XXB (123 mg, 95%) and was used in the next step without further purification. 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.34 (m, 8H), 5.52 (s, 1H), 5.31 (t, J=1.5 Hz, 1H), 5.10 (d, J=12 Hz, 1H), 5.07 (d, J=12 Hz, 1H), 5.06 (broad s, 1H), 4.72 (dd, J=12, 5 Hz, 1H), 4.62 (d, J=14 Hz, 1H), 4.50 (dd, J=12, 10 Hz, 1H), 4.22 (dt, J=8, 1.5 Hz, 1H), 3.58 (dd, J=10, 8 Hz, 1H), 3.43 (broad d, J=14 Hz, 1H), 3.37 (td, J=10, 5 Hz, 1H), 0.86 (s, 9H), 0.03 (s, 3H), -0.03 (s, 3H).
EXAMPLE 34
Synthesis of phenylmethyl 8β-[{(1,1-dimethylethyl)dimethylsilyl}oxy]tetrahydro-2R,2α-phenylspiro-[5H-4aα, 8aβ-1,3-dioxino[5,4-b]pyridine-7-(6H), 2'-oxirane]5-carboxylate (XXI & XXII)
To a methylene chloride (5 ml) solution of XXB (120 mg, 0.24 mmol), 3-chloroperbenzoic acid (68 mg, 0.31 mmol) was added. The mixture was stirred at 20° C. for 20 hr and more 3-chloroperbenzoic acid (75 mg, 0.34 mmol) was added. After 18 hr, the reaction mixture was diluted with methylene chloride and washed with aqueous sodium bicarbonate, water and brine. After drying (MgSO 4 ), the solvent was removed and the crude product (120 mg) was chromatographed (silica gel, hexane/ethyl acetate 75/25) to give mixture of epoxides XXI (22 mg, 18%) and XXII (70 mg, 57%). XXI 1 H NMR (CDCl 3 ) 7.49 (m, 2H), 7.36 (m, 8H), 5.55 (s, 1H), 5.14 (d, J=12 Hz, 1H), 5.07 (d, J=12 Hz, 1H), 4.79 (dd, J=12, 5 Hz, 1H), 4.49 (dd, J=12, 10 Hz, 1H), 3.97 (d, J=8 Hz, 1H), 3.85 (d, J=14 Hz, 1H), 3.71 (dd, J=10, 8 Hz, 1H), 3.39 (td, J=10, 5 Hz, 1H), 3.28 (dd, J=14, 1 Hz, 1H), 3.07 (dd, J=6, 1 Hz, 1H), 2.60 (d, J=6 Hz, 1H), 1.60 (broad s, 1H), 0.82 (s, 9H), 0.03 (s, 3H), -0.04 (s, 3H). XXII 1 H NMR (CDCl 3 ) 7.49 (m, 2H), 7.36 (m, 8H), 5.56 (s, 1H), 5.11 (s, 2H), 4.87 (dd, J=12, 5 Hz, 1H), 4.55 (dd, J=12, 10 Hz, 1H), 4.07 (d, J=9 Hz, 1H), 3.93 (d, J=15 Hz, 1H), 3.91 (dd, J=10, 9 Hz, 1H), 3.40 (td, J=10, 5 Hz, 1H), 3.37 (d, J=15 Hz, 1H), 3.11 (d, J=5 Hz, 1H), 2.70 (d, J=5 Hz, 1H), 0.82 (s, 9H), 0.01 (s, 3H), -0.07 (s, 3H).
EXAMPLE 35
Synthesis of 1,5-dideoxy-3-O-[(1,1-dimethylethyl)dimethylsilyl]-2-C-methyl -1,5-imino-4,6-O-(R-phenylmethylene)-D-glucitol (XXIII)
To a solution of XXI (22 mg, 0.04 mmol) in tetrahydrofuran (3 ml), lithium aluminum hydride (20 mg, 0.5 mmol) was added. After refluxing for 2 hr, the reaction mixture was cooled to room temperature and diluted with ethyl acetate. After stirring for 15 min., the reaction was carefully quenched by adding drops of 1N HCl and diluted with water. The mixture was extracted with ethyl acetate and the organic layer was washed with water and brine. After drying (MgSO 4 ), the solvent was removed and the crude product (23 mg) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give XXIII (8 mg, 57%). 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.37 (m, 3H), 5.46 (s,1H), 4.36 (dd, J=11, 5 Hz, 1H), 3.68 (dd, J=11, 10 Hz, 1H), 3.60 (d, J=10 Hz, 1H), 3.39 (dd, J=10, 9 Hz, 1H), 2.68 (d, J=11 Hz, 1H), 2.22 (d, J=11 Hz, 1H), 2.21(s, 1H), 2.16 (ddd, J=10, 9, 5 Hz, 1H), 1.57 (s, 3H), 0.86 (s, 9H), 0.06 (s, 3H), -0.08 (s, 3H).
EXAMPLE 36
Synthesis of 1,5-dideoxy-2-C-methyl-1,5-[{(phenylmethoxy)carbonyl}imino]-4,6-O-(R-phenylmethylene)-D-mannitol (XXIV)
To a solution of XXII (70 mg, 0.14 mmol) in tetrahydrofuran (5 ml), lithium aluminum hydride (23 mg, 0.57 mmol) was added. After refluxing for 4 hr, the reaction mixture was cooled to room temperature and diluted with ethyl acetate. After stirring for 15 min., the reaction was carefully quenched by adding drops of 1N HCl and diluted with water. The mixture was extracted with ethyl acetate and the organic layer was washed with water and brine. After drying (MgSO 4 ), the solvent was removed and the crude product (50 mg) was chromatographed (silica gel, hexane/ethyl acetate 1/1) to give XXIV (12 mg, 21%) 1 H NMR (CDCl 3 ) 7.48 (m, 2H), 7.37 (m, 8H), 5.58 (s,1H), 5.16 (d, J=12 Hz, 1H), 5.10 (d, J=12 Hz, 1H), 4.77 (dd, J=12, 5 Hz, 1H), 4.60 (dd, J=12, 10 Hz, 1H), 4.28 (d, J=14 Hz, 1H), 3.93 (dd, J=10, 9 Hz, 1H), 3.50 (d, J=9 Hz, 1H), 3.23 (td, J=10, 5 Hz, 1H), 2.80 (d, J=14 Hz, 1H), 2.61 (broad s, 1H), 2.32 (broad s, 1H), 1.30 (s, 3H).
EXAMPLE 37
Various illustrative compounds synthesized above were tested for inhibition of visna virus in vitro in a plaque reduction assay (Method A) or for inhibition of HIV-1 in a test which measured reduction of cytopathogenic effect in virus-infected synctium-sensitive Leu-3a-positive CEM cells grown in tissue culture (Method B) as follows:
Method A
Cell and Virus Propagation
Sheep choroid plexus (SCP) cells were obtained from American Type Culture Collection (ATCC) catalogue number CRL 1700 and were routinely passaged in vitro in Dulbecco's Modified Eagles (DME) medium supplemented with 20% fetal bovine serum (FBS). SCP cells were passaged once per week at a 1:2 or 1:3 split ratio. Visna was titrated by plaque assay in six-well plates. Virus pools were stored at -70° C.
Plaque Reduction Assay
SCP cells were cultured in 6-well plates to confluence. Wells were washed two times with serum free Minimal Essential Medium (MEM) to remove FBS. 0.2 ml of virus was added per well in MEM supplemented with 4 mM glutamine and gentamycin. After 1 hour adsorption, the virus was aspirated from each well. The appropriate concentration of each compound in 5 ml of Medium 199 (M-199) supplemented with 2% lamb serum, 4 mM glutamine, 0.5% agarose and gentamycin was added to each well. Cultures were incubated at 37° C. in a humidified 5% CO 2 incubator for 3-4 weeks. To terminate the test; cultures were fixed in 10% formalin, the agar removed, the monolayers stained with 1% crystal violet and plaques counted. Each compound concentration was run in triplicate. Control wells (without virus) were observed for toxicity of compounds at the termination of each test and graded morphologically from 0 to 4. 0 is no toxicity observed while 4 is total lysing of the cell monolayer.
96 Well Plate Assay
The 96 well plate assay was performed similarly to the plaque assay above with modifications. SCP cells were seeded at 1×10 4 cells per well in 0.1 ml DME medium. When confluent, the wells were washed with serum free MEM and 25 μl of virus added in M-199 supplemented with 2% lamb serum. After 1 hour, 75 μL of medium containing test compound was added to each well containing virus. After 2-3 weeks incubation the cytopathic effect of the virus was determined by staining with a vital stain. Cell viability was measured by determining stain density using a 96 well plate reader.
Control wells without virus were completed to determine the toxicity of compounds.
Method B
Tissue culture plates were incubated at 37° C. in a humidified, 5% CO 2 atmosphere and observed microscopically for toxicity and/or cytopathogenic effect (CPE). At 1 hour prior to infection, each test article was prepared from the frozen stock, and a 20 μl volume of each dilution (prepared as a 10×concentration) was added to the appropriate wells of both infected and uninfected cells.
On the 9th day post-infection, the cells in each well were resuspended and a 100 μl sample of each cell suspension was removed for use in an MTT assay. A 20 μl volume of a 5 mg/ml solution of 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT) was added to each 100 μl cell suspension, and the cells were incubated at 37° C. in 5% Co 2 for 4 hours. During this incubation MTT is metabolically reduced by living cells, resulting in the production of a colored formazan product. A 100 μl volume of a solution of 10% sodium dodecyl sulfate in 0.01N hydrochloric acid was added to each sample, and the samples were incubated overnight. The absorbance at 590 nm was determined for each sample using a Molecular Devices V max microplate reader. This assay detects drug-induced suppression of viral CPE, as well as drug cytotoxicity, by measuring the generation of MTT-formazan by surviving cells.
Assays were done in 96-well tissue culture plates. CEM cells were treated with polybrene at a concentration of 2 μg/ml, and an 80 μl volume of cells (1×10 4 cells) was dispensed into each well. A 100 μl volume of each test article dilution (prepared as a 2×concentration) was added to 5 wells of cells, and the cells were incubated at 37° C. for 1 hour. A frozen culture of HIV-1, strain HTVL-III B , was diluted in culture medium to a concentration of 5×10 4 TCID 50 per ml, and a 20 μl volume (containing 10 3 TCID 50 of virus) was added to 3 of the wells for each test article concentration. This resulted in a multiplicity of infection of 0.1 for the HIV-1 infected samples. A 20 μl volume of normal culture medium was added to the remaining wells to allow evaluation of cytotoxicity. Each plate contained 6 wells of untreated, uninfected, cell control samples and 6 wells of untreated, infected, virus control samples.
Table I, below, sets forth the results of the assay for the compounds XVIA, XVIB and XVIC compared to the N-butyl DNJ antiviral agent described in U.S. Pat. No. 4,849,430, which was used as a control standard, in Method B: These results are stated in terms of the ID 50 (medium inhibitory dose) and TD 50 (medium toxic dose).
______________________________________Anti HIV Activity of 2-Methyl Carbinol Analogs ##STR15##Compd. (R) R.sub.4 ID.sub.50 (μg/ml) TD.sub.50 (μg/ml)______________________________________n-Bu H 34 >500XVIA (n-Bu) Me 237 20% (500)XVIB [(CH.sub.2).sub.3 Ph] Me 492 40% (500)XVIC [CH.sub.2 CH(Et).sub.2 ] Me 6 349______________________________________
EXAMPLE 38
Intermediate 2-C-methyl-4,6-O-benzylidene-1-deoxynojirimycin (XIV), prepared in Example 22, above, was tested for inhibition of HIV by the assay of Example 37 and found to have and ID 50 of 513 μg/ml in Method B.
The antiviral agents described herein can be used for administration to a mammalian host infected with a virus, e.g. visna virus or in vitro to the human immunodeficiency virus, by conventional means, preferably in formulations with pharmaceutically acceptable diluents and carriers. These agents can be used in the free amine form or in their salt form. Pharmaceutically acceptable salt derivatives are illustrated, for example, by the HCl salt. The amount of the active agent to be administered must be an effective amount, that is, an amount which is medically beneficial but does not present toxic effects which overweigh the advantages which accompany its use. It would be expected that the adult human dosage would normally range upward from about one milligram of the active compound. The preferable route of administration is orally in the form of capsules, tablets, syrups, elixirs and the like, although parenteral administration also can be used. Suitable formulations of the active compound in pharmaceutically acceptable diluents and carriers in therapeutic dosage form can be prepared by reference to general texts in the field such as, for example, Remington's Pharmaceutical Sciences, Ed. Arthur Osol, 16th ed., 1980, Mack Publishing Co., Easton, Pa.
Various other examples will be apparent to the person skilled in the art after reading the present disclosure without departing from the spirit and scope of the invention. It is intended that all such other examples be included within the scope of the appended claims. | Novel 2-alkyl carbinol derivatives of deoxynojirimycin (DNJ) and the chemical synthesis of these derivatives and intermediates therefor from DNJ and their method of inhibiting lentiviruses are disclosed. | 2 |
FIELD OF THE INVENTION
This invention relates to the field sample rate converting of digital signals. More particularly, the present invention relates to a sample rate conversion method that employs an integer accumulator to calculate the timing relation of input and output samples.
BACKGROUND OF THE INVENTION
In many electronic applications, signals are represented and processed digitally. Digital words, or samples, represent the value of the data at a regular time interval. This regular interval is often referred to as the sample rate, and is typically expressed in units of kilohertz (kHz) representing the reciprocal of the sample interval time period.
There are situations when the available sample rate of the data is different from the desired sample rate. Depending on the characteristics of the sample data and how much the available and desired rates differ, several approaches may be used to convert the signal at one sample rate to a signal at another sample rate without intentionally altering the meaning of the signal.
A first common technique for sample rate reduction is called decimation. It is the method of choice when the available sample rate is an integer multiple of the desired sample rate. The decimator reduces the input sample rate by an integer number d to create an output sample rate. If the input signal contains high frequency components, they must be first removed by a low pass filter to avoid aliasing effects. The rate reduction is performed by simply discarding d-1 input samples for every d:th output samples.
The main drawback of decimation is that the rate reduction is limited to an integer number. In addition, an anti-aliasing filter, if necessary, may be very computationally intensive.
A second common technique for sample rate conversion is known as interpolation. Interpolation is the method frequently used for increasing the sample rate by an integer multiple. To increase the sample rate by I, the basic interpolator inserts I-1 samples with a value of zero between every input sample. The resulting samples are then filtered through an anti-aliasing low pass filter at the higher rate.
The interpolation method has some of the same basic drawbacks as decimation. The rate increase is limited to an integer number and the low pass filtering, which is necessary for interpolation, is costly.
By themselves, interpolation and decimation can only achieve changes in sample rate of an integer number. In many cases, this does not give the necessary flexibility. By combining interpolation and decimation, perhaps in several stages, it becomes possible to fine tune the sample rate conversion. For example, if the input sample rate is 194.4 kHz and the desired sample rate is 153.6 kHz, the rates do not differ by an integer factor. Instead, the desired rate is related to the available rate by the ratio 64/81. To achieve the desired sample rate, the data may first be interpolated by a factor of 64 and then decimated by a factor of 81; however, large interpolation and decimation factors put very tough constraints on the required low pass filters. To reduce the filter requirements, the interpolation and decimation may be performed in several stages, for example: interpolation by 8, followed by decimation by 9, followed by interpolation by 8, followed by decimation by 9, resulting in a total of a 64/81 conversion. Using a combination of interpolation and decimation enables a wider range of rate conversions that is not limited to integer numbers. However, the big drawback of such an approach is the cost of filtering.
Another technique for sample rate conversion method that is useful when input and output rates are close is known as linear interpolation. This method uses a first order linear interpolation approach to estimate each output sample as a function of two input samples and the relative position in time of the input and output samples. Referring to FIG. 1, the value of the m:th output sample would be calculated according to the following formula:
y.sub.m =x.sub.*n k+x.sub.n+1 *(1-k)
where
k=((n+1)*T.sub.x -m*T.sub.y)/T.sub.x
In these formulas, x n is the n:th input sample, y m is the m:th output sample, T x is the input sample period, and T y is the output sample period. Given T x is the input sample period, the time of the n:th input sample is: tx n =n*T x . Similarly, the time of the m:th output sample is: ty m =m*T y . To calculate output sample number m, chose n so that: n*T x ≦m*T y <(n+1)*T x .
One drawback of the first order interpolation method is that it may be difficult to tell which particular input samples to use for calculation of an output sample. T x and T y are seldom integers and round off errors may cause the wrong samples to be chosen. The calculation of k, which involves the subtraction of two numbers that grow very large when m and n grow, also gets susceptible to errors due to limited numeric precision.
These drawbacks can be mitigated by using a table with k-values. Continuing with the example of 194.4 kHz input and 153.6 kHz output rate, the samples relative positions in time repeat over a period of 81 input samples. Thus, it is possible to pre-calculate and store the k-values in a table. Using a table would eliminate the need to calculate k for every sample at the expense of storing pre-calculated values. The drawback with using a pre-calculated table is that the values for the tables must be pre-calculated and stored, which requires additional hardware resources. This is particularly problematic when the same converter is to be used with various input sample rate and output sample rate combinations.
SUMMARY OF THE INVENTION
The present invention is a method and apparatus for sample rate conversion that overcomes some of the drawbacks of the prior art. The method of the present invention is an interpolation method that provides the robustness of a table based approach without the need to pre-calculate and store a table. The method also simplifies the calculations involved and is less sensitive to numeric round off errors. The method utilizes an integer accumulator to generate an output data stream including a plurality of output samples at one sample rate based on an input data stream including a plurality of input samples at another sample rate. More particularly, the method uses the integer accumulator to track the timing relation between input samples and output samples. Based on the value of the accumulator, the method determines if the correct input samples are being used to calculate the current output sample. If so, the output sample is calculated as a function of the input samples and the accumulator value. By employing simple integer arithmetics to maintain the accumulator value, the present inventive method avoids unnecessarily large computations otherwise required to confirm that the proper input samples are being used while maintaining the flexibility and compactness of a non-table based approach.
The apparatus of the present invention includes an input sample register, an integer accumulator, and preferably a bit shift register, all configured so as to practice the present inventive sample rate conversion method.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram depicting linear interpolation.
FIG. 2 is a logical flowchart of the present sample rate conversion method.
FIG. 3 is a diagram depicting the timing relation between input samples ( . . . x n-3 , x n-2 , x n-1 , x n , x n+1 , . . . ) and output samples ( . . . y m-2 , y m-1 , y m , y m+1 , . . . ).
FIG. 4 is a logical flowchart of a simplified sample rate conversion method applicable when A is known to be smaller than B.
FIG. 5 is a logical flowchart of a simplified sample rate conversion method applicable when A is known to be larger than B.
FIG. 6 is block diagram of a preferred embodiment of the apparatus for a sample rate converter.
FIG. 7 is a logical flowchart of a preferred embodiment of the controller for the apparatus of FIG. 6 using the method of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described more fully hereinafter by referring to the drawings, in which a preferred embodiment is depicted. However, the present invention can take on many different embodiments and is not intended to be limited to the embodiments described herein.
The present inventive method is a variation of interpolation that uses an integer accumulator 220 to facilitate calculation of the relative position in time of input and output samples. For linear interpolation, the method employs two positive integer constants, A and B, to calculate the timing relation of two input samples and one output sample. If the sample period of the input signal is T x and the sample period of the output signal is T y , then A and B are chosen such that the ratio of A and B satisfies the following equation:
A/B=T.sub.x /T.sub.y
The actual value, or size, of A and B depends on the desired level of precision and other considerations. In effect, the input sample period T x is quantized into A steps. By keeping the steps small (keeping A large), the added quantization noise can be kept small. However, using a large number of bits to represent A may waste hardware resources. For example, assume that the input signal is available at a 194.4 kHz sample rate and the desired output sample rate is 153.6 kHz, then
A/B=T.sub.x /T.sub.y =((1/194,400)/(1/153,600))=153,600/194,400=64/81
Thus, the input sample period could be quantized into 64 steps (A=64), or any multiple of 64 steps and still maintain the proper ratio while allowing both A and B to be integers. Thus, A could be 1024 if B is 1296. However, if A is 64 then only 6 bits are required to represent the value (2 6 =64), but if A is 1024, 10 bits are required (2 10 =1024). Note that one additional bit may be required to represent sign for both.
The values of A and B are employed to iteratively calculate the value of a variable "acc" which tracks the relative positions in time for a pair of input samples and a given output sample. In simple terms, acc serves two functions. First, acc is used to determine if the proper pair of input samples is being used to calculate the current output sample. Second, acc is used to assign the proper weighting to each member of the input sample pair so as to properly estimate the output sample value. The details of how acc performs these functions will become apparent through the following description.
FIG. 2 shows a logical flow chart for the present invention. At the start of the process, the integer accumulator 220 is set to zero and the variables m and n are also set to zero (box 10). Variable m is an integer counter representing the sequence number of the current output sample. Variable n is an integer counter representing the sequence number of the current input sample. As will become apparent from the following description, the only purpose of m and n in the flow diagram is to aid the reader in understanding the algorithm by clarifying how the input and output samples are related. Neither m nor n need be stored or calculated to practice the present inventive method.
The accumulator 220 contains an integer value representing the variable "acc." The main processing loop begins by adding A to the integer value in the accumulator 220 (see box 20). Acc is then checked to see if it is less than zero (box 30). If so, then n is incremented by one (box 40), the next input sample is selected to assume the role of the current input sample, and the process returns to box 20. If acc is not less than zero, then the output sample is calculated (box 50). In simple terms, the acc value check of box 30 represents a determination of whether the particular output sample being calculated falls within the current input sample period, i.e., between the two currently selected input samples (n and n+1) or exactly at input sample x n+1 .
For purposes of the invention, the current input sample period is defined as the time period from the current input sample to the next subsequent input sample. Thus, if the input sample rate is 1 Hz, and the current input sample is number four (in the sequence zero, one, two, three, four, . . . n) then the current input sample period is from 4 seconds to 5 seconds.
Calculating the output sample (box 50) is accomplished via the formula:
y.sub.m =(acc*x.sub.n +(A-acc)*x.sub.n+1)/A
This formula is a modified linear interpolation formula. In this formula, x n is the value of the last input sample which occurs before the output sample and x n+1 is the value of the first input sample after the output sample. In the situations where an output sample falls directly on top of an input sample, then acc will equal the integer zero and formula will collapse to y m =(A*x n+1 )/A=x n+1 . Thus, the value of the properly corresponding input sample, x n+1 , will be used for the output sample (y m ). Note, however, that for the special case of the very first instance of direct overlap, at the first input sample (x 0 ) and first output sample (y 0 ), acc will equal A, therefore the formula for this one instance will collapse to y 0 =(A*x 0 )/A=x 0 .
After the output sample is calculated (box 50), the value of acc is decremented by B (box 60). In box 70, this new value of acc is checked to see if it is greater than or equal to zero. If so, m is incremented by one and the process returns to box 50. If not, then the both m and n are incremented by one (box 90). In simple terms, the acc value check of box 70 represents a determination of whether the next output sample occurs within the same pair of input samples.
The process continues looping through the main processing loop (box 20-box 100) until there are no more samples (box 100), at which point it stops (box 110). In this manner the input sample rate of period T x is converted to an output sample rate of period T y .
As an example of the method in action, see FIG. 3. Assume that the input sample rate is faster than the output sample rate, meaning that A is smaller than B. For sake of discussion assume that A is 10 and B is 14, corresponding to an input sample rate of 1.4 kHz and an output sample rate of 1.0 kHz. Further, assume that the conversion process is proceeding according to the present invention and is now processing input sample x n-3 and output sample y m-2 . At this point, entering box 20, acc equals -4. At box 20, acc is incremented by A such that acc now equals 6 (-4+10). Because 6 is larger than 0 (box 30), output sample y m-2 is calculated (box 50) based on x n-3 and x n-2 . Now, acc is decremented by 14 (box 60) so as to equal -8 (+6-14). Because acc is not greater than 0, the main process loop begins again. During this second pass through the main process loop, the value for y m-1 is calculated using x n-2 and x n-1 and acc is adjusted to be -12 (-8+10-14). At the third pass through the main process loop, acc is incremented by A so as to equal -2 (-12+10). Now, because acc is still less than 0, the current input sample (x n-1 at this point) is discarded, the next input sample x n assumes the position of current input sample, and acc is increased to 8 (-2+10). Output sample y m is then calculated using x n and x n+1 . At the conclusion of the third pass through the main process loop (box 100), acc equals -6 (8-14). As shown in FIG. 3, the reason input samples x n and x n+1 were used to calculate output sample y m rather than input samples x n-1 and x n is that y m fell between x n and x n+1 .
As can be seen from this explanation, the variable acc is used to dynamically track the timing relation between input samples and output samples. In this example, where A is less than B, the input sample sequence is advanced by an "extra" one or more position when acc is less than zero at box 30. In other situations, when B is less than A, two or more output samples may be calculated using the same input sample pair when acc is greater than or equal to zero in box 70. Thus, it can be seen that variable acc is used by the process to verify that the correct input sample pair is being used to calculate each given output sample.
The algorithm of FIG. 2 can be simplified slightly if the constant A is known to be greater than the constant B, or vice versa. Using the same reference numbers, FIG. 4 shows a simplified logical flow chart for when A is known to be smaller than B. FIG. 5 shows a simplified logical flow chart for when A is known to be larger than B. The flow charts of FIG. 4 and FIG. 5 show that a comparison and loop back step can be eliminated when the relationship between A and B is known, thereby simplifying the process.
For the above processes, the calculation of the output sample (y m ) calls for division by the constant A. Because division is sometimes expensive to implement in hardware, it is possible to pre-calculate the value of 1/A instead, and use multiplication. Alternatively, and more preferably, a value for A can be selected that enables easy division. For example, if A is a power of two, the division can be implemented as a simple binary bit shift.
For purposes of an example, assume that the input sample is available at 194.4 kHz and the desired sample rate is 153.6 kHz. This means that
A/B=T.sub.x /T.sub.y =153,600/194,400=64/81
Thus, A could equal 64 and B could equal 81. If so, then the input sample period T x would be divided into 64 steps. Greater precision could be obtained if, for example, A were increased to 1536 and B were correspondingly increased to 1944. Preferably, however, A would be a large power of two such as 1024 (2 10 ), meaning that B would be 1296. If A is 1024, then division could be implemented as a binary right shift of ten (10).
The discussion above assumes utilization of a linear interpolation approach. However, the present inventive method is can also be utilized for other interpolation approaches, such as second order or cubic or other methods known in the art. Some of these other interpolation approaches require the use of more than two input samples to calculate a given output sample. If only two input samples are required, then only one integer accumulator 220 need be employed. If more than two input samples are required, a plurality of integer accumulators 220 may be used to track the various timing relations between input samples and output samples. Alternatively, one accumulator 220 can be employed to track the relationship between all the input samples required and the output sample to be calculated; this is because once a timing relationship to one input sample is known, the timing relationship to the other input samples will simply be an integer increment of A farther away. If a different interpolation approach (other than linear) is used, obviously a different formula would also be employed to calculate each given output sample. However, the output sample value would still be a function of at least a plurality of input samples and one or more accumulator values.
A block diagram of a possible hardware implementation of the sample rate converter 200 is shown in FIG. 6. The sample rate converter 200 includes a controller 210, an integer accumulator 220, a multiplexer 230, adders 240, 250, a subtractor 260, multipliers 270, 280, an input sample register 290, and a bit shifter 300. The controller 210 controls the overall function of the converter 200. The accumulator 220 tracks the relative position in time of input and output samples using integer arithmetics. The multiplexer 230 is connected to sources 180, 190 for values of A and B. The input samples are sequentially fed to the register 290. The bit shifter 300 performs the appropriate bit shift to reflect division by A and outputs the output sample value for each output sample.
Alternatively, the functions of the controller 210 may be distributed within the converter 200 rather than collected in a single device as shown in FIG. 6. Also, two or more of the components of the converter 200, such as the adders 240, 250, subtractor 260, multipliers 270, 280, and input sample register 290 may be combined into an integrated arithmetic logic unit, but this may be more costly.
The FIG. 7 shows a simplified flowchart of the preferred operation of the controller 210 of FIG. 6 for the method described in FIG. 4. Upon initialization, the controller 210 instructs the accumulator 220 to clear and the input sample register 290 to load the first input sample (box 310). Note that this action corresponds to box 10 of FIG. 4. Then the controller 210 verifies that the next input sample is available (box 320). If not, the controller 210 loops until the next input sample is available. If so, then the controller 210 instructs the multiplexer 230 to load A and causes the accumulator 220 to increment by A (box 330). Note that this action corresponds to box 20 of FIG. 4. The controller 210 then checks the sign bit of the accumulator 220 (box 340). Note that this action corresponds to box 30 of FIG. 4. If the sign bit is positive, the controller 210 causes the output sample (y m ) to be calculated, the multiplexer to switch to -B, and the accumulator 220 to add -B to the existing accumulator value (box 350). These actions correspond to boxes 50, 60, and 90 of FIG. 4. Either after box 350 or if the sign bit is negative at box 340, the controller 210 causes the input sample register 290 to load the next input sample (box 360).
The converter 200 of FIG. 6 is a simple hardware implementation of the linear interpolation sample rate conversion method described above for when A is a power of two. The converter 200 is capable of converting the sample rate of an input sample stream of x 1 , x 2 , . . . x n to an output sample stream of y 1 , y 2 , . . . y m having a different output sample rate using integer arithmetics. By making A and B programmable constants, the same sample rate converter 200, may be programmed to operate at several different input to output sample ratios. | A sample rate converter is described for converting an input data stream including a plurality of input samples at one sample rate to an output data stream including a plurality of output samples at another sample rate. The converter uses an interpolation approach that utilizes an integer accumulator to track the timing relation between input samples and output samples. Based on the value of the accumulator, the method determines if the correct input samples are being used to calculate the current output sample. If so, the output sample is calculated as a function of the input samples and the accumulator value. The converter provides the robustness of a table based conversion approach without the need to pre-calculate and store a table, simplifies the calculations involved, and is less sensitive to numeric round off errors. | 7 |
This invention relates generally to a material handling system, and more particularly to apparatus for guiding, aligning, feeding, sewing, cutting and stacking garment components.
Although the invention will be described in conjunction with the application of a reinforcing binding fabric to precut fabric panels used in the fabrication of briefs, the basic concepts are susceptible to other uses wherein a first fabric-like material is directed in a prescribed manner while a second fabric-like material is sewn thereto.
Briefly, the invention includes an assembly for directing and sewing fabric materials, an assembly for cutting fabric, and an assembly for stacking the fabric materials.
The assembly for directing and sewing fabric materials folds a first binding web, which serves as a reinforcing member, over the edge of a garment panel or component before being selectively secured together in a predetermined fashion by sewing instrumentalities. The assembly includes various mechanisms for straightening and feeding the fabric materials to the cutter assembly. A series of panels are sequentially advanced by an operator to the sewing instrumentalities of a conventional sewing machine where they are sewed to the binding web and carried by the binding towards the cutting assembly.
The cutting or chopper assembly is mounted downstream of the machine's sewing zone and includes angularly disposed chopper blades attached to a linkage and controlled by a fluid operated actuator. Upon receipt of a single signal the actuator displaces the linkage in a first direction to move the chopper blades from a rest position to a cutting position, and back to the rest position. The cutter assembly serves to cut the binding intermediate to adjacent garment panels sewn to and being advanced by the fabric binding. The discrete garment components, each consisting of a panel sewn to a binding, are sequentially advanced to the stacking assembly.
The stacking assembly includes a conveyor for sequentially advancing the discrete components to a drop plate. The drop plate is selectively displaced for discharging each component onto a stack tray. The stack tray position below the drop plate is controlled by an elevator mechanism.
One of the primary objects of the invention is the provision of a new and improved system for sewing fabric panels to a fabric reinforcing member, severing the reinforcing member intermediate the panels to define discrete fabric components, and stacking of the components in a prescribed manner.
Another object of the invention is the provision of a new and improved system for increasing production while reducing the skill required to operate the apparatus for sewing the fabric materials.
A further object of the invention is the provision of a chopper assembly having plural, angularly disposed cutting edges for simultaneously severing portions of the reinforcing member.
Still another object of the invention is the provision of a new and improved garment component stacking assembly.
These and other objects of the invention will become more fully apparent by reference to the appended claims and as the following detailed description proceeds in reference to the figures of the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic perspective view of a portion of the system for sewing and stacking garment components;
FIG. 2 is a schematic top plan view of the apparatus of FIG. 1;
FIG. 3 is a fragmentary, rear elevational view of the apparatus of FIG. 1;
FIG. 4 is an enlarged perspective view of a portion of the machine illustrating the cutter or chopper assembly and the binding drive belt;
FIGS. 5a-5c are schematic side elevational views of the chopper assembly, partly in section, illustrating displacement of the blades during one stroke of the fluid cylinder;
FIG. 6 is a fragmentary, top elevational view of the apparatus illustrating the relationship of a panel with respect to the binding, and the various mechanisms for aligning, guiding and advancing the panels;
FIG. 7 is a schematic, fragmentary, perspective view of the apparatus illustrating the stacking assembly conveyor, drop plate and stack tray;
FIG. 8 is a schematic diagram of the controls for the chopper assembly and the stacking conveyor belt and drop plate;
FIG. 9 is a schematic control diagram for the elevator mechanism of the stacking assembly;
FIG. 10 is a schematic electrical diagram for activating various components of the systems; and
FIG. 11 is a top plan view of a garment component.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawing, and particularly to FIG. 1, the apparatus 20 includes a guiding, aligning, feeding and sewing system 22 mounted upon a support structure 24 for the joining of fabric panels 26 to reinforcing binding fabric 28.
The apparatus incorporates a conventional folding and guiding device 30 for folding a continuous supply of binding fabric 28 into a predetermined relationship prior to the binding reaching the sewing instrumentalities 32 and presser foot 34 of a conventional sewing machine 36. The binding 28 moving through device 30 is fed under the presser foot 34 of the sewing machine as long as the sewing machine is in operation. When an operator properly aligns a fabric panel 26 in close proximity to the sewing instrumentalities 32 and binding 28, and activates the sewing machine by means of a foot treadle 38 or other suitable means, the panel 26 and binding 28 will move in unison and be sewn together.
Depressing the machine foot treadle simultaneously initiates several other machine functions. The cloth straightener wheel 40 begins to rotate in a counterclockwise direction, as viewed from the front of the machine, air is discharged through a small air jet 42, the cloth brush 44 begins to rotate, a vacuum source 43 is activated to remove any binding waste material through opening 46 in the cloth plate 48, and the cloth wheel 50, the binding wheel 52, and the binding drive belt 54 are activated. The air jet opening 42 is angled downwardly to direct air against panel 26 and urge it downwardly while straightening the portion remote to binding 28.
As the operator guides a fabric panel 26 into alignment with the binding 28 and toward the sewing instrumentalities, the cloth straightener wheel 40, which may be provided with soft bristles, rotates in a direction which tends to urge the panel away from the binding thus straightening and removing wrinkles from the panel 26. The wheel 40 may be driven in a conventional manner by a motor 41 located below plate 48.
The binding drive belt 54 extends around two pulleys or rollers 56, 58, FIG. 4, and is driven from the sewing machine motor 55 by means of shaft 79, belt 73 and pulleys 75, 77, drive unit 72, and shaft 57 which is connected by a coupling, not shown, to shaft 59 supporting the pulley 58.
The binding drive belt 54 conveys the binding as it leaves the sewing machine presser foot 34 and the loose forward end of the binding is drawn by suction into the waste opening 46 in the plate 48 and subsequently to a waste receptacle, not shown. As a panel 26 is sewn into the binding 28, it slides upon plate 48 as it is carried along by the binding 28. The leading edge of the panel 26 is blown aside by the small air jet 42 just as it goes under the driven cloth wheel 50. Thus a portion of the panel 26 is attached to the binder and is being advanced by drive belt 54, while a portion is being advanced by cloth wheel 50. The leading edge of the panel 26 intermediate belt 54 and wheel 50 is positioned to activate a photoelectric sensor 60, FIG. 4, which functions to operate a cutting or chopper assembly 62, and to deactivate the vacuum source which normally draws the waste binding into opening 46 as it will be subsequently described.
The cloth wheel 50 is positioned to normally substantially engage the cloth plate 48 and is driven by means of chain and sprocket drive assemblies 64, 66, drive shafts 68, 70, drive unit 72, belt 73 and pulleys 75, 77, and shaft 79 connected to the sewing machine motor 55.
The panel 26 attached to the binding 28 is also advanced by cloth brush 44 which is driven by motor 80. Note that the brush 44 is supported for rotation in bearing blocks and is angularly disposed, with respect to the direction of movement of the panel and binding through the machine, urging the panel in a direction away from the binding to facilitate removal of wrinkles from the panel and flattening of the panel upon plate 48.
The binding wheel 52 is driven from shaft 68 by means of sprocket drive assembly 82 and shaft 84 and advances the binding 28 and panel 26 attached thereto towards the stacking assembly 88. The binding wheel 52 applies tension to the binding 28 extending between wheel 52 and the binding drive belt 54 to assist in cutting of the binding upon activation of the chopper assembly 62. After the binding 28 has been severed, the garment component 90, which consists of a fabric panel 26 attached to a severed length of binding 28, is fed by the binding wheel 52 until the leading edge goes under the stacking assembly conveyor belt 92.
Referring particularly to FIGS. 4-6, the chopper assembly 62 provides a novel, instantaneous, double angle cut of the binding 28. The angle of cut of leading and trailing edges of a length of binding sewn to a panel 26 serves to taper the end portions of the binding into the panel edge thus eliminating unevenness and bulkiness of the garment components adjacent the ends of the binding 28 which results in improved appearance and comfort to a wearer. As shown by FIG. 6, the two cutting blades define an angle of approximately 90° such that the angle of cut of the binding adjacent the leading edge of a panel is angled approximately 45° in one direction while the end of the binding adjacent the trailing end of the panel is angled approximately 45° in the opposite direction. The assembly includes spaced parallel supports 96, 98 which pivotably mount, in suitable bearings, pivot pin 99 which has a linkage 100 mounted thereon. The linkage includes a pair of spaced, parallel members 102, 104 having aligned openings adjacent each other for receiving pins 106, 108.
The blade support 110 is movable along vertical guideways of the supports 96, 98 such that each angularly disposed blade 122, 114 secured thereto is capable of displacement in a vertical plane while the lower cutting edges of each blade remain parallel with the upper surface of cloth plate 48. The blades are displaceable by means of a bar or link 116 pivotably coupled at one end to the blade support 110 by means of a pin 118, and pivotably coupled at the opposite end, by pin 106, to the linkage 100. The rod 120 of a double acting fluid cylinder 122 is pivotably coupled to the linkage 100 by means of pin 108.
The chopper assembly performs two double angled cuts through binding 28 for each cycle of the fluid cylinder 122. Referring to FIG. 5a, the blades and blade support 110 are in the full up position and the rod is attracted within the cylinder. Upon the continuous admission of fluid into the cylinder 122 through conduit 126, the rod 120 begins moving to the left, FIG. 5b, and the blades 112, 114 are displaced vertically downwardly into engagement with a block member 130 of nylon or other suitable material having an upper surface flush with the polished cloth plate 48. Any binder fabric 28 located below the blades would be severed along two angularly disposed lines. Note that at this point the piston 132 attached to rod 120 is approximately midway of the length of the cylinder housing. As fluid continues to be admitted through conduit 126, the piston rod 120 moves further to the left, FIG. 5c, and pin 108 pivots over the top center of pin 99 and the blades and support 110 move back to the uppermost position. Note that the blades move from a retracted position into cutting engagement with the nylon member 130 and again back to a retracted position during one stroke of the piston and piston rod. Another complete chopping action is achieved as fluid is admitted into cylinder 122 through conduit 128 and the piston and piston rod 120, 132 move to the right, FIGS. 5c, 5b, 5a.
Reciprocation of the chopper blades could alternately be accomplished by means of a rotary fluid cylinder, if desired.
Once the binding has been severed by the chopper assembly, the garment component 90 consisting of the severed length of binding and a fabric panel 26 having an inwardly curved edge is advanced by the binding wheel 52 to the stack conveyor belt 92.
The conveyor belt 92 passes around rollers 140 and 142 mounted upon shafts 68 and 144, respectively. The belt 92 normally is driven from the sewing machine motor at a speed comparable to that of binding wheel 52 and cloth wheel 50. When a component 90 starts into position between the lower run of belt 92 and the drop plate 152 the conveyor belt must speed up to rapidly position the component over the drop plate in order for the drop plate to deposit the component upon stack tray 166 and complete its operational cycle before a subsequent component 90 is advanced to the belt 92. In order to permit the increase in speed of belt 92, conventional one-way clutches 138 are provided intermediate belt roller 140 and shaft 68. Shaft 144 supporting roller 142 is driven only when the conveyor speed is to be increased. The shaft 146 is selectively driven upon actuation of fluid cylinder 151 through pulleys 148, 150 and belt 146. This increase in speed, permitted by the one-way clutches, is necessary in order to permit the stacking assembly to stack the component and for the drop plate 152 to move back to its original position for receiving a subsequent component.
The drop plate 152 mounted generally parallel to and in close proximity to the lower rung of conveyor belt 92 is pivotably coupled to the upper ends of parallel lengths 154, 156 by a pin 158. The lower ends of the lengths 154, 156 are pivotably mounted upon the frame 24.
Reciprocation of the drop plate 152 is accomplished by a fluid motor 160 which drives an eccentrically mounted arm 162 connected to the lengths 154, 156 by an adjustable linkage 164. When the motor 160 and linkage begin retracting the drop plate 152 to the right, FIG. 3, the panel drops onto the stack tray 166. After a predetermined time period, the drop plate returns to its original FIG. 3 position. The stacking assembly is now ready to receive the next component 90.
The position of the stack tray 166 is controlled by an elevator mechanism which includes a double acting fluid cylinder 170. In order to eliminate wrinkling or uneven stacking of the garment components 90 upon tray 166, the tray or uppermost component of a stack of components should be located in close proximity to the drop plate 152, when the plate 152 is in the FIG. 3 or FIG. 7 positions, so that a component can be properly positioned upon the stack as the drop tray is retracted to the right, FIG. 3, and a component 90 is released. As the stack of components gets higher, the tray lowers to keep the top of the stack in about the same position. The stack tray 166 is attached to the rod 172 of fluid cylinder 170 and mounted upon a frame assembly 174 for vertical displacement upon movement of the rod of the cylinder. The cylinder 170 is mounted upon frame assembly 174, the lower end of which is pivotably mounted upon support structure 24. During the formation of a stack of components, the frame assembly 174 normally is in the FIG. 3 position; however, when a full stack of components 90 have been stacked upon the tray 166, an air cylinder 176 may be operated to tilt the frame assembly 174 to the left, from the FIG. 3 position, about the pivotably mounted lower end, to provide operator access to the loaded tray 166 and facilitate removal of the stacked components. FIG. 2 shows a tray 166 and frame 174 tilted to provide access to the tray. Also mounted upon the tiltable frame 174 are a pair of air-oil tanks 254, 256, one being in series with each port of the double acting cylinder 170.
The top of the stack of components 90 is sensed by a photoelectric mechanism 182 secured to the support structure 24 just below the drop plate 152. The photoelectric sensor controls the location of the top of the stack of components through the air-oil tanks and cylinder 170, as will be subsequently described.
The operation of the system will now be described. An operator actuates a manual switch 200 which turns on the sewing machine motor 55. The operator then properly positions and aligns a panel 26 in front of the sewing instrumentalities of the sewing machine using both hands. Depressing the treadle 38 operates the sewing machine motor clutch 202 which initiates operation of the sewing machine instrumentalities 32. The clutch also simultaneously activates a microswitch 204 which, in turn, activates the brush motor 80, brush motor 41, a solenoid valve 206 which permits the discharge of air from jet 42, and a valve 208 which controls vacuum source 43 which draws any waste material through opening 46 in the cloth plate 48. Actuation of the clutch 202 also drives the binding drive belt 54, the binding wheel 52, the cloth wheel 50 and the conveyor belt 92 through the various pulleys, belts and shafts previously described. The operator then feeds the panel to the sewing instrumentalities and guides the panel with his right hand while at the same time rotation of the cloth straightener wheel 40 straightens the wrinkles in the panel.
The binding drive belt 54 applies downward pressure to the binding 28 sliding along polished plate 48 as the binding leaves the presser foot, and the loose forward end of the binding is drawn through waste takeaway opening 46 by the vacuum source 43. As the panel 26 is sewn to the folded binding 28 it is carried along by the binding.
The leading edge of the panel 26 is blown aside by the small jet at 42 just as the panel goes under the driven cloth wheel 50 which then holds it aside so that the leading edge is in the proper position to break the light beam directed from light source 61 through opening 60, FIG. 4, in cloth plate 48 and triggers a photoelectric sensor transducer 210 and amplifier 212, FIG. 8. Breaking of the beam initiates several actions. A signal is directed from the amplifier 212 to a waste timer 214 and subsequently to a pilot valve 208 which deactivates the vacuum source 43 so that the panel 26 can pass freely over the opening 46. Suction is normally applied when the beam is unbroken. A signal from amplifier 212 also is directed to a one-shot circuit 218 which sends one pulse through OR circuit 220, lockout timer 222, a toggle action flip-flop circuit 224, and chopper solenoid operated valve 226 which activates chopper cylinder 122 causing an instant chop. The lockout timer 222 is provided to give the chopper time to complete its stroke by serving to block out any of the signals before the chop is completed. The panel 26 attached to binding 28 continues to be conveyed by the cloth brush 44, cloth wheel 50, and binding drive belt 54, and the binding wheel 52 until the leading edge of the panel goes under the conveyor belt 92 which conveys onto the drop plate 152.
When the trailing edge of the panel 26 covers the photoelectric sensor 60 a timer 230 is activated and the vacuum source 43 is reactivated. At this point one of three things happens. The timer may time out and cause the chopper 62 to chop and activate the stacker assembly. The leading edge of the next panel, fed by the operator and also attached to the binding 28, covers the photoelectric sensor and the chopper 62 chops in the same manner as with the first panel. Alternately the timer 230 times out and sends a pulse from one-shot circuit 232 simultaneously to the chopper solenoid operated valve 226 to activate the chopper 62 and to activate the stacker assembly 88. If a subsequent panel 26 follows a preceding panel so closely that the chopper does not have time to complete its cycle before the sensor 60 is again covered, the signal will be ignored and the chopper will not operate. Another possibility is that a subsequent panel 26 covers the sensor 60 before the timer times out. In the event this happens, the pulse or signal from the circuit 218 will cancel the timer causing an instant chop of the binding and activation of the stacker.
To activate the stacker, the pulse from unit 232 starts a timer 234 which through solenoid operated valve 236 causes the fluid cylinder or motor 151 to instantaneously drive the conveyor belt 92 through pulleys 148, 150, drive belt 146 and shaft 144 at a rate of speed which is much greater than the speed that shaft 57 normally drives the belt. This increase in speed is due to the clutches 138 and the one-way clutch of the binding wheel 52 which quickly pulls the component 90 onto the drop plate 152 in a position to be deposited upon the stack tray. When the timer 234 times out the stack conveyor actuator 151 returns to the initial position and timer 234 activates drop plate timer 240, which through solenoid operated valve 242 controls fluid cylinder 160 to tilt and retract the drop plate 152 to the right, FIG. 3, to drop the garment component 90 onto the stack tray 166. When timer 240 times out the fluid cylinder 160 returns the drop plate 152 to its original position. The stacker assembly is now ready to receive the next component 90.
As the stack of components 90 in the tray 166 builds up, the tray is lowered to maintain the top of the stack at a preselected elevation and spaced a predetermined distance below the drop plate 152. The tray 166 is displaceable generally vertically by the double acting air cylinder 170. The air cylinder is controlled by photoelectric sensor 182 (FIG. 7), timer 250, flip-flop circuit 252, valve 262 and air-oil tanks 254, 256. A two-way lock or brake valve 258 is in series with cylinder 170 and between the cylinder and air-oil tank 256. This valve 258, which is controlled by a pilot valve 260, acts as a lock to hold the stack tray 166 in a given position by preventing flow of oil from the lower portion of cylinder 170. The four-way directional valve 262 supplies air pressure selectively to the upper portions of air-oil tanks 254, 256 to power the cylinder 170 either up or down. The valve 262 is controlled by a pilot valve 264 which receives a signal from flip-flop circuit 252.
When the stack tray 166 is at rest, the four-way directional valve 262 is in the down position and the valve 258 is closed. If the beam of the photoelectric sensor 182 is broken, due to the buildup of the stack of components 90, a signal is directed through timer 250 and OR circuit 261 and the valve 258 is opened permitting the tray 166 to move downwardly. When the beam is restored, the valve 258 closes locking the stack tray in position.
To facilitate precise stacking of the components and to prevent inaccurate positioning of the stack tray 166, the tray 166 and stack of components thereon is adjusted periodically. A seek timer 270 times out every ten seconds. If the light beam of sensor 172 is not broken, the two-way valve 258 will open and four-way valve 262 will shift causing the tray 166 and stacked components to move upward towards the beam. When the beam is broken the four-way valve 262 shifts to the down position, and the tray 166 and stack of components 90 will move down until the beam is restored. The valve 258 then closes locking the tray 166 in position.
When a predetermined number of panels 26 having binding 28 applied thereto are stacked upon the tray 166, the operator actuates a switch 272 which through pilot valves 274, 264 and four-way valve 262 and valve 276 causes fluid cylinder 176 to tilt the elevator assembly to the left, FIG. 3, and the tray 166 moves to the full up position to assist in unloading of the garment components. | A material handling system includes an assembly for feeding, directing and sewing fabric materials, an assembly for cutting fabric, and an assembly for stacking fabric. The feeding and sewing assembly folds a reinforcing binding web over the edge of a garment panel and sews the two together before they are advanced by the binding to the cutter assembly. The cutting assembly includes angularly disposed blades for simultaneously severing the binding web intermediate adjacent garment panels. The stacking assembly includes a conveyor for sequentially advancing severed garment panels to an elevator mechanism for receiving the panels. | 3 |
This is a division of application Ser. No. 07/014,018, filed Feb. 12, 1987.
BACKGROUND OF THE INVENTION
The field of the invention is tobacco and antismoking products (deterrents) and the present invention is particularly concerned with agonists and antagonists to nicotine.
The state of the art of tobacco smoking deterrents may be ascertained by reference to U.S. Pat. Nos. 4,276,890 and 4,311,691 of FICHERA and U.S. Pat. No. 4,579,858 of FERNOE et al, the disclosures of which are incorporated herein by reference.
Fernoe et al are aware of the prior art nicotine containing chewing gums as disclosed in U.S. Pat. Nos. 865,026; 940,521; 3,877,468; 3,901,248 and 3,845,217 and state that it seems particularly difficult to find other smoking substitutes equivalent to or as effective as these nicotine containing chewing gums. U.S. Pat. No. 4,579,858 discloses a smoking substitute composition for application directly into the nose, consisting essentially of an aqueous solution of nicotine or a physiologically acceptable acid addition salt thereof, having a pH value of 2 to 6, containing 10 to 0.5% w/v of nicotine calculated as the free base, containing a nasally-acceptable thickening agent, having a viscosity not less than 100 centipose, and having about 0.5 to 5 mg nicotine per every 0.05 to 0.5 ml thereof and a method of diminishing the desire of a subject to smoke, which comprises the step of administering to the subject intranasally this smoking substitute composition.
The patents of Fichera disclose that the approach used by Fernoe et al has the difficultly that a physiological dependence upon nicotine remains and that until this dependence is overcome, the opportunity to resume smoking is very high. U.S. Pat. No. 4,311,691 defines a composition for inhibiting tobacco smoking comprising a gamma pyrone and an inert physiologically acceptable carrier capable of providing sustained release of the gamma pyrone in the mouth over a time period of at least ten (10) minutes, in unit dosage form containing from 20 mg to 300 mg of gamma pyrone per unit dose and a chewing gum composition for inhibiting tobacco smoking comprising a chewing gum base having particulate ethyl maltol distributed uniformly throughout, providing 100 mg to 300 mg ethyl maltol per stick of gum.
U.S. Pat. No. 4,276,890 defines the method of inhibiting tobacco smoking of smokers without physiological symptoms of nicotine withdrawal comprising smoking while awake during the waking hours of the day and administering to such a smoker 500 mg to 1500 mg total daily dose of ethyl maltol or maltol as a gamma pyrone divided into several incremental doses during the waking hours of the day, each incremental dose being retained in the smoker's mouth and released therein over a period of at least 10 minutes, for at least about 5 to 10 days, for a total of about 20 to 30 days or at least until there results either of a gradual decrease in the number of cigarettes smoked and the length of time they are smoked or until such point as the lowered tobacco consumption rate becomes obvious.
Fichera has contributed the discovery that the administration of maltol or ethyl maltol at appropriate dosage levels and rates, significantly reduces the tobacco consumption of habitual smokers.
SUMMARY OF THE INVENTION
Applicant has discovered compounds and compositions which are agonists and antagonists to nicotine and therefore are useful as smoking deterents.
The nicotinic agonists and antagonists described in this invention are useful in treating the smoking habit. An agonist, such as dimethylaminoethylmethylcarbamate or methylcarbamylcholine, being pharmacologically similar to nicotine, substitute for nicotine at the receptors. Since they are readily metabolized by esterases and resemble the endogenous neurotransmitter, acetylcholine, the agonists are less habit forming.
The antagonists, on the other hand, are prescribed for the treatment of the tobacco habit by virtue of their ability to displace and compete with nicotine at the receptors, thereby preventing the pharmacologic effects of nicotine both on the peripheral and central nervous system.
These nicotine agonists and antagonists are capable of preventing the seizures, prostration, elevated blood pressure, and mortality resulting when various doses of nicotine are administered systemically or intraven-tricularly to rats.
The compounds exhibit specificity for nicotinic receptors as determined by their ability to compete with 3 H-nicotine and 3 H-methylcarbamylcholine for binding to rat brain membranes. The binding affinity of the compounds for the nicotinic receptors showed an excellent correlation with the pharmacologic potency of the antagonists.
The compounds are useful for counteracting the toxic effects of nicotine and related substances. The substances are useful for counteracting the cardiovascular and behavioral effects of nicotine and related substances.
Those compounds which are methylcarbamyl esters of dialkylaminoalkyl alcohols are nicotinic agonists, i.e., act similarly to nicotine in their cardiovascular, autonomic, and psychotropic action. An example is methylcarbamylcholine.
The nicotinic antagonists have the following structural requirements:
(1) Aromatic, cycloalkyl, and heterocyclic carbamic acid esters of di- and trialkylaminoalkyl alcohols.
(2) Aromatic, cycloalkyl, and heterocyclic thiocarbamic acid esters of di- and trialkylaminoalkyl alcohols.
(3) Aromatic, cycloalkyl, and heterocyclic carboxylic acid esters of di- and trialkylaminoalkyl alcohols.
(4) Aromatic, cycloalkyl, and heterocyclic carboxylic acid esters of heterocyclic amino alcohols.
(5) Lobelia alkaloids: lobeline, lobelanine, and lobelanidine.
The nicotinic agonists (nicotine-like) have the following structural requirements:
(1) Methylcarbamic acid esters of di- and trialkylaminoalkyl alcohols.
(2) methylthiocarbamic acid esters of di- and trialkylaminoalkyl alcohols.
The compounds of the present invention can be administered according to the methods and compositions disclosed in U.S. Pat. Nos. 4,276,890, 4,311,691 and 4,579,858.
A unit dosage of 1 mg to 100 mg is advantageous and this dosage is administered three times a day. When the agonists and antagonists are admistered in chewing gum, a stick of gum contains 1 mg to 100 mg of the antagonist or agonist.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pH curve for 3 H-MCC and 3 H-nicotine wherein:
the open dots= 3 H-nicotine; the solid dots= 3 H-MCC.
B=moles bound ×10 -14 .
FIG. 2 is a Scatchard plot of [ 3 H]-MCC binding to rat brain membranes.
The plot represents a study from three separate examples with coefficient of variation of the K d and B max values being under 8%. A 1000-fold excess of unlabeled ligand was used at each concentration of radioligand to obtain specific binding. B=amount bound and F=concentration of free 3 H-MCC.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One of the agonists of the present invention is a new radioligand, [ 3 H]-methylcarbamyl choline and it has been used as an agonist at the nicotinic cholinergic and nicotine-like binding sites in rat brain membranes. A Scatchard analysis with the radioligand yielded a K d of 1.1×10 -9 M and a B max of 4.0×10 -14 moles/mg protein which compares with a lower affinity site for (-)0[ 3 H]-nicotine having a K d of 3×10 -9 M and a B max of 2×10 -14 moles/mg. Comparable values for the K d were obtained from a Hill plot and from calculations based on rate constants for association and dissociation. A comparison of the binding affinity of various nicotine analogues, nicotinic cholinergic agents and other neurotropic agents revealed a close similarity between the two radioligands, with the exception that quaternization of nicotine or carbamate esters increased affinity by at least an order of magnitude with [ 3 H]-methylcarbamyl choline and resulted in a comparable decrease in affinity with [ 3 H]-nicotine as the ligand. The binding of [ 3 H]-methylcarbamyl choline, like [ 3 H]-nicotine, was not displaceable by muscarinic cholinergic antagonists. It was concluded that although [ 3 H]-methylcarbamyl choline and [ 3 H]-nicotine bind to a common receptor in the brain, the functional and chemical characteristics of the receptor(s) differ in some respects from peripheral nicotinic cholinergic receptors.
In the course of evaluating the structure-activity relationships of the [ 3 H]-nicotine binding sites to rat brain membranes and purified receptor, it was observed that carbamylcholine and substituted carbamate esters of choline exhibited a relatively high affinity for the nicotine site. At a concentration of 10 -9 M S-(-)-[ 3 H]-nicotine, N-methylcarbamyl choline had an IC 50 value of 8×10 -9 M as compared to a value of 2×10 -9 M for unlabeled nicotine. Since carbamate esters of choline are considerably more stable than acetylcholine, an evaluation was undertaken with [ 3 H]-methylcarbamyl choline of high radioactive specific activity to determine its similarity to the [ 3 H]-nicotine and [ 3 H]-acetylcholine binding sites in rat brain membranes. A number of studies with [ 3 H]-acetylcholine, prepared enzymatically with [ 3 H]-acetic acid, have alluded to the similarity in the receptor binding characteristics of the two ligands.
The present evaluation demonstrates the effectiveness of [ 3 H]-methylcarbamyl choline ([ 3 H]-MCC) as a ligand for use as an agonist at the nicotine-like and nicotinic cholinergic binding sites in brain tissue.
EXAMPLE 1
Synthesis Of DMAE Methylcarbamate And MCC
To 0.05 moles of dimethylaminoethanol in 100 ml of dry toluene was added 0.07 moles of methylisocyanate, and the mixture was refluxed for 16 hours. After removal of the solvent in vacuo, the viscous liquid was taken up in 25 ml of CHCl 3 and extracted with H 2 O. Upon removal of the CHCl 3 , a white oily product was obtained and the final product was recovered after distillation in vacuo at 1 mm and a temperature of 135° C. The yield was 85%.
An infrared analysis of DMAE methylcarbamate yielded the following bands:
1730, 1540, 1385, 1100, 960, 995 790 cm -1
Methylcarbamylcholine was prepared by adding 0.012 moles of methyl iodide to 0.010 moles of DMAE methylcarbamate in 50 ml acetone and allowing the reaction to proceed overnight at room temperature. The white crystalline material was filtered, washed with 50 ml of ethyl ether, and dried. The yield was 98%. Analysis by mass spectroscopy yielded the following fragment with % relative abundance:
58 (100%), 142 (27%), 28 (21%), 57 (12%), 71 (8%), 42 (8%), 30 (7%), 56 (6%), 59 (6%), 44 (6%)
[ 3 H]-MCC was prepared by New England Nuclear by quaternization of DMAE methylcarbamate with [ 3 H]-CH 3 I. The purity of the [ 3 H]-MCC was verified by HPLC.
Measurement Of [ 3 H]-MCC And [ 3 H]-nicotine Binding
The procedure for preparation of rat brain membranes and for measuring specific [ 3 H]-MCC and [ 3 H]-nicotine binding is described by ABOOD et al in Neurochem. Res 10, 260 (1985). Membranes were obtained from whole rat brain after homogenization in 30 volumes of 0.05M NaPO 4 , pH 7.0, and centrifugation at 50,000×g for 30 minutes. To a 2 ml polypropylene tube was added 2 mg membrane protein along with various concentrations of either [ 3 H]-MCC (specific activity=80 Ci/mmole) or (-)-[ 3 H]-nicotine (New England Nuclear, specific activity=75 Ci/mmole) with or without various concentrations of unlabeled nicotine, nicotine analogues, carbamate esters and other agents, in a final volume of 1.2 ml 0.05M NaPO 4 , pH 7.0. The relationship of pH to the binding of the two ligands was determined with 0.05M NaPO 4 buffer. All assays were performed in triplicate. After incubating in an ice bath (0°-4°) for 30 minutes, the tubes were centrifuged in an Eppendorf centrifuge for 2 minutes and the pellet washed twice by filling the tubes with buffer and aspirating. The bottom of the tubes were then cut off (animal nail clipper) and counted by liquid scintillation.
Psychotropic Evaluation Of Various Agents
The psychotropic action of the various agents was determined by administering various doses into the fourth ventricle through chronically implanted cannulae, as described by Abood et al, Neurosci. Biochem. 5 479 (1981). A dose of 4 nmoles of (-)-nicotine in 1 μl resulted in prostration of all four limbs, while 2 nmoles (IC 50 ) produced prostration in the hind limbs and some weakness in the forelimbs.
RESULTS
Comparison Of pH Curve Of 3 H-MCC And 3 H-nicotine Binding
The pH curves for both 3 H-MCC and 3 H-nicotine binding had a pH optimum around 6.5 (FIG. 1). Although the shape of the curves were similar, the change in pH on either side of the optimum was considerably greater for 3 H-MCC
Scatchard Analysis Of [ 3 H]-MCC Binding
A Scatchard plot of [ 3 H]-MCC in the presence of unlabeled MCC was linear, yielding a K d of 1.1×10 -9 M and a B max of 4.0×10 -14 moles/mg protein of whole rat brain membranes (FIG. 2). Replacement of unlabeled MCC with unlabeled (-)-nicotine also yielded a linear Scatchard with comparable K d and B max values. A Hill plot of the data [log (B/B-B max vs log F)] yielded a Hill binding constant of 9×10 -10 M, which is in close agreement with the K d determined by Scatchard analysis.
K d Calculation From Rate Constants For Association And Dissociation
The rate constants for association for [ 3 H]-MCC binding to rat brain membranes was determined to be 3.0×10 5 M -1 sec -1 ; and for the dissociation 1.0×10 -3 sec -1 . The K d , calculated from the ratios of the rate constants, was 3.3×10 -9 M, a value which is in close agreement with that obtained by Scatchard analysis.
Comparison Of Various Agents In Competition With [ 3 H]-MCC And [ 3 H]-nicotine
A variety of nicotine and cholinergic agents were compared for their ability to compete with [ 3 H]-MCC and [ 3 H]-nicotine binding to rat brain membranes (Table 1). At a concentration of 1 nM of [ 3 H]-nicotine, unlabeled (-) and (+)-nicotine had IC 50 values of 3×10 -9 and 1×10 -8 M, respectively. With either radioligand, increasing the alkyl chain length on the pyrrolidine N resulted in 3-fold decrease with the N'-ethyl and a 200-fold decrease in affinity with the N'-propyl analogues of nicotine The affinity of N'-nicotonium was about 3 orders of magnitude less than (-)-nicotine with both radioligands. Comparable affinities with both radioligands were observed with the various carbamate esters, MCC having an affinity approaching that of (-)-nicotine. The K d value for acetylcholine was 5×10 -5 M while that of hexamethonium, α-bungarotoxin, QNB and atropine was greater than 1×10 -4 M.
TABLE 1______________________________________PROCEDURE DATA______________________________________Scatchard analysis K.sub.d = 1.1 × 10.sup.-9 M B.sub.max = 4.0 × 10.sup.-14 moles/mg proteinHill Pot K.sub.d = 9 × 10.sup.-10 MRate Constants 3.3 × 10.sup.-9 M______________________________________ K.sub.d determination by various analytic procedures.
Phychotropic Action Of Various Agents
The various agents were compared for their ability to induce prostration following administration into the rat fourth ventricle (Table 2). The (-)-enantiomer of nicotine was 20 times more effective than the (+)-enantiomer and 10, 40 and 50 times more potent than the N'-ethyl, N'-propyl, and nicotonium analogues, respectively Among the carbamate esters, MCC had 1/5 the potency of (-)-nicotine, while the others were relatively weak or inactive. The remainder of the agents, including acetylcholine, were inactive.
TABLE 2______________________________________ [.sup.3 H]-nicotine [.sup.3 H]-MCC IC.sub.50 IC.sub.50 Prostration M M EC.sub.50______________________________________(-)-nicotine 3 × 10.sup.-9 8 × 10.sup.-9 2(+)-nicotine 1 × 10.sup.-8 9 × 10.sup.-8 40N'-methyl nicotonium 7 × 10.sup.-6 4 × 10.sup.-6 100N'-ethyl nornicotine 3 × 10.sup.-8 1 × 10.sup.-7 20N'-propyl nornicotine 6 × 10.sup.-7 1 × 10.sup.-6 80DMAE methyl- 5 × 10.sup.-7 8 × 10.sup.-7 300carbamateMCC 8 × 10.sup.-9 6 × 10.sup.-9 10DMAE carbamate 1 × 10.sup.-5 1 × 10.sup.-5 >300carbamylcholine 4 × 10.sup.-7 1 × 10.sup.-6 100acetylcholine 6 × 10.sup.-5 5 × 10.sup.-6 >100hexamethonium >1 × 10.sup.-4 >1 × 10.sup.-4 IAα-bungarotoxin >1 × 10.sup.-4 >1 × 10.sup.-4 IAQNB >1 × 10.sup.-4 >1 × 10.sup.-4 IAatropine >1 × 10.sup.-4 >1 × 10.sup.-4 IA______________________________________ Comparison of IC.sub.50 values for binding of various agents using [.sup. H]-nicotine and [.sup.3 H]-MCC as radioligands.
To determine psychotropic potency expressed as EC 50 , at least 6 rats were used for every agent. DMAE=dimethylaminoethyl; QMB=3-quinuclidinyl benzilate. The IC 50 values were determined from plots of various concentrations of agents. EC 50 values were based on data from 6 rats. IA=inactive.
DISCUSSION
The present example has demonstrated that the receptor binding characteristics of [ 3 H]-MCC to rat brain are similar to those of [ 3 H]-nicotine; however, the Scatchard plot for [ 3 H]-MCC was linear while that for [ 3 H]-nicotine was biphasic. A similar K d was derived from dissociation-dissociation rate constants and from a Hill plot. The lower affinity site for [ 3 H]-nicotine had a K d of 3×10 -9 M and B max of 1×10 -14 moles/mg membrane protein which compares favorably with the values for [ 3 H]-MCC. With [ 3 H]-nicotine, a higher affinity site with a K d of 2×10 -10 M and B max of 0.5×10 -14 moles/mg was not seen with [ 3 H]-MCC. Although [ 3 H]-acetylcholine also appears to have similar binding characteristics to [ 3 H]-nicotine, [ 3 H]-MCC affords the advantages that it is chemically more stable and is more readily prepared. Another similarity between 3 H-MCC and 3 H-nicotine binding was the pH curve with an optimum of 6.5. A major difference between the two ligands is that [ 3 H]-acetylcholine, but not [ 3 H]-MCC binding, is displaceable by low concentrations of muscarinic antagonists When muscarinic agonists, such as [ 3 H]-oxotremorine-M disclosed by Birdsall et al in Mol. Pharmacol. 14, 723 (1978) and [ 3 H]-cis methyldioxolane disclosed by EHLERT et al in Life Sci. 26, 961 (1980) are employed as radioligands IC 50 values are obtainable with muscarinic antagonists in the nanomolar range. Since MCC is closely related to carbamylcholine, which is a muscarinic agonist and readily binds to the muscarinic cholinergic receptor, this finding was unexpected.
Although the relative binding affinity of a variety of nicotine analogues and other agents is similar with both radioligands, there is one striking difference. With either radioligand, quaternization of the pyrrolidine N of nicotine reduces the affinity by 3 orders of magnitude; whereas, quaternization of the carbamate esters results in about a 50-fold increase in affinity (compare DMAE methylcarbamate with MCC). It is also noteworthy that the psychotropic potency following intraventricular administration decreases 50-fold with quaternization of nicotine, while increasing over 10-fold after quaternization of DMAE methyl carbamate. The diminished psychotropic potency of N'-methylnicotonium is anomalous in view of the fact that when administered systemically, it is more potent than nicotine in producing seizures and mortality in rats or mice. This difference in the central and peripheral action and receptor affinity of nicotine and N'-methyl nicotonium suggests a difference in the nature of the two receptors. Binding studies with [ 3 H]-nicotine indicate that there may be at least two, and possibly more, nicotinic sites in rat brain; whereas, with [ 3 H]-MCC only one site is evident, which is presumably similar to the lower affinity site for nicotine. The functional significance of the low and high affinity sites for nicotine is not known. Since 1-2 μl of a 10 -3 M solution of nicotine administered into the fourth ventricles is required to produce prostration, it appears likely that the lower affinity site is associated with the psychotropic response. Since MCC and other carbamate esters of alkylaminoalcohols are chemically similar to acetylcholine, it would appear that MCC is interacting with a nicotinic site in brain, while being virtually inactive at a muscarinic cholinergic site.
Insofar as the binding characteristics of [ 3 H]-nicotine resemble those of [ 3 H]-MCC, both ligands evidently bind to the same receptor. The extremely low affinity of acetylcholine [4 orders of magnitude less than (-)-nicotine and MCC] and its correlative lack of psychotropic activity, when supersaturating concentrations of acetylcholine are administered intraventricularly leave partly unexplained the functional and biochemical nature of the sites. A similar disparity between the binding affinity and function of acetylcholine has been observed in the Torpedo electric organ which exhibits both a low and high affinity site for the nicotine antagonist, α-bungarotoxin as disclosed by Conti-Tronconi et al in Biochem. Biophys. Res. Comm. 107, 123 (1982). Presumably, occupancy of the low affinity site by acetylcholine activates the ionic channel while occupancy of the high affinity site leads to desensitization; so that a nicotinic antagonist may prevent channel activation without occupying the recognition site as disclosed by Conti-Tronconi et al in Ann. Rev. Biochem. 51, 491 (1982). It is possible that either the higher affinity site involves a desensitized cholinergic receptor or that MCC and nicotine function as agonists at a high affinity recognition site whose relationship to acetylcholine remains obscure.
EXAMPLE 2
The present example discloses the synthesis and pharmacology of a number of carbamytes, cycloalkyl, and aryl esters of choline and other aminoalkyl alcohols with high affinity for the nicotinic binding site and which are effective antagonists to the psychotropic and other pharmacologic effects of nicotine.
There are multiple binding sites for (-)-nicotine in brain membranes. In addition to a high and low affinity binding site, there appears to be an allosteric site responsive to both (+)- or (-)-nicotine. The site exhibits positive cooperativity to both nicotine enantiomers when either (+)- or (-)- 3 H-nicotine is used as the ligand.
METHODS
Measurement Of 3 H-nicotine And 3 H-MCC Binding
The procedure for preparation of rat brain membranes and for measuring specific 3 H-nicotine and 3 H-MCC binding is disclosed in Example 1. Membranes were obtained from whole rat brain after homogenization in 30 volumes of 0.05 M NaPO 4 , pH 7.5, and centrifugation at 50,000×g for 30 min. To a 2 ml polypropylene tube was added 2-3 mg membrane protein along with various concentrations of either 3 H-MCC (specific activity=80 Ci/mmole) or (-)- 3 H-nicotine (New England Nuclear, specific activity=75 Ci/mmole) with or without various concentrations of unlabeled nicotine, nicotine analogues, carbamate esters, and other agents, in a final volume of 1.2 ml 0.05 M NaPO 4 buffer containing 0.1 M NaCl at pH 7.5, or 8.5 in the case of (+)- 3 H-nicotine. All assays were performed in triplicate. After incubating in an ice bath (0°-4°) for 30 min., the tubes were centrifuged in an Eppendorf centrifuge for 2 min. and the pellet washed twice by filling the tubes with buffer and aspirating. The bottom of the tubes was then cut off (animal nail clipper) and counted by liquid scintillation.
Pharmacologic Measurements
The psychotropic action of the agents was determined by assessing their ability, when administered intraventricularly (i.v.c.), to produce prostration (agonists) or prevent the nicotine-induced prostration (antagonists) by the procedure described in Example 1. The agents were administered into cannulae chronically implanted into the fourth ventricle of Sprague-Dawley male rats (200-250 g), in 1 μl volumes. A typical prostration response, occurring within 1-3 sec. following the injection of 2 nmoles of nicotine, generally involved all four limbs with body and neck muscles. Antagonism was determined by administering the test agent 1 min. prior to giving 2 nmoles of nicotine. Antagonism was also determined by measuring an agent's ability to prevent nicotine-induced seizures. The test agent was administered intraperitoneally (i.p.) 7 min. prior to the administration of 1.5 mg/kg nicotine i.p. A third method was to determine a test agent's ability to prevent lethality produced by 3 mg/kg nicotine i.p.
Arterial blood pressure was determined by means of a Gould Statham P23ID pressure transducer attached to the right femoral artery of rats anesthetized with 60 mg/kg sodium pentothal i.p. and connected to a polygraph. Various doses of test agent were administered 1 min. prior to the administration of a dose of nicotine (0.05 mg/kg) which resulted in a 42±20 mm Hg elevation of systolic blood pressure. The mean dose of a test agent necessary to completely block the hypertensive action of nicotine was determined.
RESULTS
Comparison Of Various Ester Agonists With 3 H-nicotine And 3 H-MCC Binding And Their Psychotropic Potency
The various esters were compared for their ability to compete with 3 H-nicotine and 3 H-MCC binding to rat brain membranes, utilizing a concentration of 1×10 -9 M of each radioligand, which yielded an IC 50 value for nicotine of 2×10 -9 M and 6×10 -9 M for 3 H-MCC. TMAE carbamate (carbamylcholine) had an IC 50 of 4×10 -7 M and 1×10 -6 for 3 H-nicotine and 3 H-MCC, respectively, whereas the corresponding DMAE derivative had a value of 1×10 -5 M with either radioligand. The most potent agent was TMAE methylcarbamate (methylcarbamyl choline) with an IC 50 value of 8×10 -9 M and 6×10 -9 , compared to a value of 5×10 -7 M and 8×10 -7 for the two radioligands, respectively, for the DMAE analogue. No difference was noted in the IC 50 values between TMAE acetate (acetylcholine), TMAE succinate (succinylcholine), and their corresponding DMAE analogues, all having values of about 5×10 -5 M with either radioligand. The one exception was acetylcholine which had a 10-fold greater affinity with 3 H-MCC than with 3 H-nicotine.
Comparison Of Various Ester Antagonists For Binding And Blockade Of Prostration
Among the various esters, TMAE Benzoate was the most effective compound in blocking nicotine-induced prostration when both compounds were administered into the fourth ventricle of rats; next in effectiveness and of comparable activity were TMAE phenylcarbamate, TMAE phenylthiocarbamate, TMAE phenylacetate, and DMAE nicotinate. The quaternary esters were generally 10-fold more potent than the tertiary analogues, both with respect to their binding affinity and psychotropic action. The most potent of the compounds tested was the natural alkaloid, α-lobeline, which exhibited an even greater affinity than (-)-nicotine for the receptor and blocked the nicotine-induced prostration with a dose of 10 nmoles i.v.c. Other agents exhibiting some binding affinity were procaine and 9-aminotetrahydroacridine. The other agents listed, including cocaine and atropine, were inactive.
Antagonism Of Various Esters To Nicotine-induced Seizures
At a dose of 1.5 mg/kg nicotine intraperitoneally, rats exhibited prostration followed by tremors, fasciculations, cyanosis and labored breathing, and myoclonic seizures as shown in Table 5 which follows. When the rats were given 20 mg/kg TMAE benzoate or TMAE cyclohexylcarboxylate 7 min. prior to nicotine, there was a 78% blockade of seizure activity. At a dose of 25 mg/kg DMAE benzoate or DMAE cyclohexylcarboxylate, about half of the rats exhibited seizures. Both TMAE phenylcarbamate and 3-quinuclidinyl benzoate afforded almost complete protection. It should be noted that muscle weakness, some tremors, and a slower respiratory rate persisted in all animals despite the antagonist. At a dose of 5 mg/kg, α-lobeline afforded complete protection against seizures. No significant behavioral effects were observed with any of the esters alone.
Protection By Various Agents Against Nicotine Mortality In Rats
At a dose of 5 mg/kg i.p., α-lobeline resulted in a 75% reduction of the mortality produced by 3 mg/kg nicotine i.p. in rats. A dose of 25 mg/kg TMAE benzoate, TMAE cyclohexylcarboxylate, TMAE phenylcarbamate, TMAE phenylthiocarbamate, and 3-quinuclidinyl benzoate resulted in 63, 66, 50, 63 and 50% protection, respectively. Atropine was ineffective.
Antagonism Of Hypertensive Action Of Nicotine
The agents were tested for their ability to completely reverse a 25% increase in systolic blood pressure following a dose of 0.05 mg of nicotine given intravenously to anesthetized rats as shown in Table 7 which follows. The most effective agent was α-lobeline at a dose of 0.2 mg/kg followed by TMAE benzoate and TMAE cyclohexylcarboxylate at 1.5 mg/kg. At higher doses, ranging from 5-10 mg/kg, all the other esters tested were also effective.
Behavioral Effects Of Agents
The behavioral effects of the various agents administered i.v.c. were assessed either alone or in combination with nicotine to determine possible antagonism. When 20 nmoles of nicotine (10 μl ) was administered i.v.c., there immediately ensued a prostration involving all four limbs and lasting 2-4 min. At 500 times this dose, carbamylcholine produced weakness in all limbs and head muscles, while DMAE carbamate had only a similar effect at 100 times the dose of nicotine. The most potent of the esters was methylcarbamylcholine which produced a prostration lasting over 20 min; but unlike the response to nicotine, the rats seemed somewhat paralyzed and unable to move their heads or limbs. At a dose of 500 nmoles, dimethylaminomethylcarbamate produced moderate weakness in the hindlimbs and head. The remainder of the compound tested alone were either inactive or had only a slight effect. All of the active compounds including nicotine produced deep diaphragmatic breathing and a decreased respiratory rate.
When 100 nmoles of benzoylcholine was administered 1 min prior to giving 20 nmoles of nicotine, the prostration response did not occur. The choline ester of benzoic acid was 5 times as effective as the DMAE ester. Procaine and cocaine, which are local anesthetics, both effectively block nicotine-induced prostration.
DISCUSSION
Example 2 demonstrates that (1) a number of newly synthesized and other esters of aminoalkyl and aminocycloalkyl alcohols and aromatic acids, and (2) α-lobeline are effective antagonists to the psychotropic and peripheral actions of nicotine and other nicotinic agonists. The most effective antagonist in blocking the prostration, seizures, and mortality following nicotine administration in rats was α-lobeline. Among the various esters of various alkylaminoalcohols, benzoylcholine was the most effective antagonist. Both antagonists also exhibited a very high affinity for brain nicotine receptors using either (-)- 3 H-nicotine or 3 H-methylcarbamylcholine as ligands. When the phenyl group of benzoylcholine was substituted with phenylalkyl, naphthoyl or phenylcarbamyl, the antagonistic potency was diminished. Replacement of the choline moiety by quinuclidinyl, piperidyl, or pyrrolidyl diminished antagonistic potency.
A series of carbamyl and alkyl esters of tertiary amino alcohols serving as agonists to the nicotine receptor, quaternization of N resulted in about a 20-fold increase in receptor affinity and a marked increase in pharmacologic potency. A similar increase in receptor affinity and antagonist potency was observed with the present series of esters acting as antagonists.
A number of miscellaneous alkoloids and esters were found to be antagonists, including procaine, a local anesthetic, and 9-aminotetrahydroacridine, an anticholinesterase. Other local anesthetics, such as cocaine and lidocaine and anticholinesterases, such as physostigmin and prostigmin are inactive.
A comparison of the chemical structures of the nicotine-like compounds with the carbamates with respect to their action on prostration reveals significant differences in the two classes of compounds. Both nicotine and 3-dimethylaminopyridine, which are arylamines, are agonists; whereas aryl esters of aminoalcohols, such as DMAE nicotinate and benzoylcholine, are antagonistic to the nicotine-induced prostration; while alkyl esters of aminoalcohols are agonists. Another striking difference is that within the series of arylamines related to nicotine, quaternization of the N'-nitrogen decreases binding affinity by 3 orders of magnitude and a virtual loss of psychotropic action, whereas in the series of alkyl esters quaternization of the aminoalcohol results in about a 50-fold increase in affinity for the nicotine receptor and a corresponding increase in psychotropic potency.
Although α-lobeline has been reported by Sollman in "A Manual of Pharmacology", 7th edition, Saunders, Philadelphia, 1948, p. 352 to suppress the desire for tobacco, the pharmacologic relationship of this natural alkaloid to nicotine is obscure. Included among the pharmacologic effects of α-lobeline are its hypertensive action resulting from the stimulation of the carotid body as disclosed by Heymans et al in L. Arch. int. Pharmacodyn, 1932, 43, 86, broncio-construction as disclosed by Cambar et al in Arch. int. Pharmacodyn. 1969, 177, 1, and bronchoarrythmia as disclosed by Korczyn et al in Arch. int. Pharmacodyn. 1969, 182, 370. It has been suggested that the cardiovascular effects are both parasympathetic (muscarinic) and sympathetic. It has been generally assumed that α-lobeline is a ganglionic stimulant resembling nicotine. The present example indicates that the alkaloid is also acting as an antagonist at nicotine receptors both centrally and peripherally.
It has been reported that N-methylcarbamylcholine was about 5 times more potent than acetylcholine or carbamylcholine in contracting rectus abdominus muscle and 40 times less potent than carbamylcholine in contracting guinea pig ileum. It has been reported that N-methylcarbamylcholine and related carbamates are metabolized by a rat liver microsomal system requiring NADP (nicotinamide adenine dinucleotide) as a coenzyme.
A number of di- and trialkylaminoalkyl N-arylcarbamates have been synthesized and shown to have herbicidal and anthelminthic as well as antileukemic and hypotensive properties.
TABLE______________________________________.sup.3 H-nicotine And .sup.3 H-MCC Binding Of Various Agents AndTheir Ability To Produce Prostration .sup.3 H-Nicotine .sup.3 H-MCC Binding Binding Prostration IC.sub.50 IC.sub.50 EC.sub.50 M M nmoles______________________________________s-(-)-nicotine 2 · 10.sup.-9 8 × 10.sup.-9 2N'-methyl nicotinium 7 × 10.sup.-6 4 × 10.sup.-6 100N'ethyl nornicotine 3 × 10.sup.-8 1 × 10.sup.-7 20N'-propyl nornicotine 6 × 10.sup.-7 1 × 10.sup.-6 80DMAE carbamate 1 × 10.sup.-5 1 × 10.sup.-5 400TMAE carbamate 4 × 10.sup.-7 1 × 10.sup.-6 100DMAE methyl- 5 × 10.sup.-7 8 × 10.sup.-7 300carbamateTMAE methyl- 8 × 10.sup.-9 6 × 10.sup.-9 10carbamateDMAP methyl- 2 × 10.sup.-7 5 × 10.sup.-8 100carbamateDMAE acetate 5 × 10.sup.- 5 5 × 10.sup.-5 >1000TMAE acetate 6 × 10.sup.-5 5 × 10.sup.-6 300(acetylcholine)DMAE succinate 5 × 10.sup.-5 6 × 10.sup.-5 1000TMAE succinate 8 × 10.sup.-7 7 × 10.sup.-7 50butyrythiocholincytisine 6 × 10.sup.-9 1 × 10.sup.-10 2______________________________________ DMAE = 2dimethylaminoethyl TMAE = 2trimethylaminoethyl DMAP = 3dimethylaminopropyl
TABLE 4__________________________________________________________________________.sup.3 H-nicotine And .sup.3 H-MCC Binding Of Various Agents AndTheir Efficacy In Blocking Nicotine-induced Prostration .sup.3 H-Nicotine .sup.3 H-MCC Blockade of Binding Binding Prostration IC.sub.50 IC.sub.50 EC.sub.50 M M nmoles__________________________________________________________________________*DMAE benzoate 1 × 10.sup.-6 100*TMAE benzoate 8 × 10.sup.-8 4 × 10.sup.-8 10DMAE cyclohexylcarboxylate 2 × 10.sup.-6 4 × 10.sup.-6 100TMAE cyclohexylcarboxylate 8 × 10.sup.-8 5 × 10.sup.-8 10DMAE phenylcarbamate 1 × 10.sup.-4 1 × 10.sup.-4 IATMAE phenylcarbamate 6 × 10.sup.-6 8 × 10.sup.-7 200DMAE phenylthiocarbamate 7 × 10.sup.-5 2 × 10.sup.-5TMAE phenylthiocarbamate 5 × 10.sup.-7 5 × 10.sup.-7 50*DMAE nicotinate 2 × 10.sup.-7 2 × 10.sup.-7 50TMAE nicotinate3-Quinuclidinyl benzoate 7 × 10.sup.-6 6 × 10.sup.-6 2003-Quinuclidinyl 3 × 10.sup.-6 2 × 10.sup.-6 100methylcarbamateDMAE phenylacetate 7 × 10.sup.-5 7 × 10.sup.-6TMAE phenylacetate 2 × 10.sup.-6 3 × 10.sup.-7 100DMAE napththoate 8 × 10.sup.-5 7 × 10.sup.-5TMAE napththoate 9 × 10.sup.-6 5 × 10.sup.-6N-methyl-3-piperdylbenzoate 3 × 10.sup.-5 2 × 10.sup.-5 300N-benzylpiperidyl IA IAmethylcarbamateN-benzyl-4-piperdyl IA IA IAmethylcarbamate*N-methyl-3- IA IA IApiperidyldiphenylacetate*atropine IA IA IAN-methyltetrahydropapavarine 7 × 10.sup.-5 8 × 10.sup.-5*9-aminotetrahydroacridine 2 × 10.sup.-5 1 × 10.sup.-5 200*procaine 7 × 10.sup.-5 3 × 10.sup.-5*cocaine >1 × 10.sup.-4 >1 × 10.sup.-4 IA*α-lobeline 5 × 10.sup.-9 .sup. 7 × 10.sup.-10 10*lobelanine 1 × 10.sup.-8 5 × 10.sup.-9 25*lobelanidine 2 × 10.sup.-8 5 × 10.sup.-9 25__________________________________________________________________________ DMAE = 2dimethylaminoethyl TMAE = 3trimethylaminoethyl IA = inactive IC.sub.50 = concentration inhibiting binding 50% EC.sub.50 = dose in nmoles producing 50% efficacy
TABLE 5______________________________________Antagonism Of Various Agents To Nicotine-inducedSeizures In RatsThe test agents were administered intraperitoneally7 min. prior to 1.5 mg/kg nicotine Except as indicated, thedose of all other agents was 25 mg/kg.Agent Seizures % Antagonism______________________________________Nicotine 10/10 --+α-lobeline 1/8 0/85 mg/kg+TMAE benzoate 1/8 78+DMAE benzoate 5/9 4550 mg/kgDMAE cyclohexylcarboxylate 4/8 5050 mg/kgTMAE cyclohexylcarboxylate 1/8 78+TMAE phenylcarbamate 1/9 89+3-quinuclidinyl benzoate 1/7 86+atropine 6/6 0______________________________________
TABLE 6______________________________________Protection Against Nicotine Mortality In Rats Byα-lobeline And Various EstersData are based on 10 rats given 25 mg/kg of testagent followed by 3 mg/kg nicotine (neutralized with HCl)5 min. later; both agents given i.p. %Agent Mortality Antagonism______________________________________(-)-nicotine 8/10 --3 mg/kg+α-lobeline 2/10 755 mg/kg+TMAE benzoate 3/10 63+TMAE cyclohexylcarbamate 3/9 66+TMAE phenylcarbamate 4/10 50+TMAE phenylthiocarbamate 3/10 63+3-quinuclidinyl benzoate 4/10 50+atropine25 m/kg______________________________________
TABLE 7______________________________________Antagonism Of Hypertensive Action Of Nicotine By VariousAgents. -The dose (±s.d.) refers to that needed in mg/kg tocompletely block a 42 ± 20 mm Hg elevation in systolic bloodpressure following the administration of 0.05 mg/kg nicotine i.v.Agent Antagonistic dose______________________________________α-lobeline 0.2 ± 0.05TMAE benzoate 1.5 ± 0.3DMAE benzoate 10.0 ± 25TMAE phenylcarbamate 5.0 ± 1.0TMAE cyclohexylcarboxylate 5.0 ± 1.5TMAE penylthiocarbamate 4.0 ± 0.83-quinuclidinyl benzoate 5.0 ± 1.2______________________________________
EXAMPLE 3
DMAP methylcarbamate
To 0.05 moles of dimethylaminopropanol in 100 ml of dry toluene was added 0.07 moles of methylisocyante, and the mixture was refluxed for 16 hours. After removal of the solvent in vacuo, the viscous liquid was taken up in 2 ml of CHCl 3 and extracted with H 2 O. Upon removal of the CHCl 3 , a white oily product was obtained and the final product was recovered after distillation in vacuo at 5 mm and a temperature of 84° C. The yield was 60%.
An infared analysis of DMAP methylcarbamate yielded the following bands:
2990, 1730, 1560, cm -1
Analysis by mass spectroscopy yielded the following:
160, 91, 70, 58
EXAMPLE 4
Quinuclidinol methylcarbamate
To 0.05 moles of 3-quinuclidinol dissolved in 100 ml of dry toluene was added to 0.07 moles of methylisocyanate and the mixture was refluxed for 8 hours. After removal of the solvent in vacuo, the mixture was taken up to 50 ml of H 2 O and extracted twice with H 2 O. After removal by CHCl 3 , the yellow oily liquid was distilled in vacuo at 5 mm Hg and 130° C. The yield was.
An infrared analysis of quinuclidinol methylcarbamate yielded the following bands:
2985, 1730, 1530, 1265 cm -1
Analysis by mass spectroscopy yielded the following:
184, 156, 58
EXAMPLE 5
DMAE And TMAE Phenylcarbamate
To 0.05 moles of dry dimethylaminoethanol in 100 ml of dry toluene was added 0.07 moles of phenylisocyanate, and the mixture was refluxed for 16 hours. After removal of the solvent in vacuo, the viscous liquid was taken up in 25 ml of CHCl 3 and extracted with H 2 O. Upon removal of the CHC 3 , a white oily product was obtained and the final product was recovered after distillation in vacuo at 5 mm at 145° C. The yield was 65%.
An infrared analysis of DMAE phenylcarbamate yielded the following bands:
1730, 1600 cm -1
Analysis by mass spectroscopy yielded the following:
212, 164, 119
TMAE phenylcarbamate was prepared by adding 0.013 moles of methyl iodide to 0.010 moles of DMAE phenylcarbamate in 50 ml of acetone and allowing the reaction to proceed overnight at room temperature. The white crystalline material was filtered, washed twice with 50 ml of ethyl ether, and dried. The yield was 90%.
EXAMPLE 6
DMAE And TMAE Phenylthiocarbamate
The conditions are the same as for DMAE and TMAE phenylcarbamate in Example 5 except that reflux was 8 hours. The product was recovered by distillation in vacuo at 5 mm and at 117° C. The yield was 58%.
An infrared analysis of DMAE phenylthiocarbamate yielded the following bands:
2990, 1725, 1550, 1225 cm -1
Analysis by mass spectroscopy yielded the following:
219, 194, 93
EXAMPLE 7
DMAE And TMAE Naphthoate
To 0.05 moles of dry dimethylaminoethanol in 100 ml of dry methylene chloride at room temperature was added slowly with stirring over a period of 15 min. 0.05 ml of napththoyl chloride in 50 ml of methylene chloride. After another 30 min. the contents were extracted with H 2 O and the organic phase concentrated in vacuo. The final product was purified by distillation at 5 mm Hg and 176° C. The yield was 55%.
An infrared analysis of DMAE naphthoate yielded the following bands:
2980, 1750, 1595, 1240 cm -1
Analysis by mass spectroscopy yielded the following:
199, 155, 127
TMAE naphthoate was prepared by adding 0.013 moles of methyl iodide to 0.010 moles of DMAE naphthoate in 50 ml of acetone and allowing the reaction to proceed overnight at room temperature. The white crystalline material was filtered, washed twice with 50 ml of ethyl ether and dried. The yield was 90%.
EXAMPLE 8
DMAE And TMAE Phenylacetate
To 0.05 moles of dry dimethylaminoethanol in 100 ml of dry methylene chloride at room temperature was added slowly with stirring over a period of 15 min. 0.05 ml of phenylacetyl chloride in 50 ml of methylene chloride. After another 30 min., the contents were extracted with H 2 O and the organic phase concentrated in vacuo. The final product was purified by distillation at 5 mm Hg and 168° C. The yield was 55%.
An infrared analysis of DMAE phenylacetate yielded the following bands:
2960, 1730, 1450, 1380 cm -1
Analysis by mass spectroscopy yielded the following:
207, 163, 142
TMAE phenylacetate was prepared by adding 0.013 moles of methyl iodide to 0.010 moles of DMAE phenylacetate in 50 ml of acetone and allowing the reaction to proceed overnight at room temperature. The white crystalline material was filtered, washed twice with 50 ml of ethyl ether and dried. The yield was 90%.
EXAMPLE 9
3-Quinuclidinol Benzoate And N-methyl-3-quinuclidinyl Benzoate
To a mixture of 0.05 moles of 3-quinuclidinol in 100 ml of dry methylene chloride at room temperature was added slowly with stirring over a period of 15 min. 0.05 moles of benzoyl chloride in 50 ml of methylene chloride. After the reaction had proceeded an additional 30 min., the contents were extracted with H 2 O and the organic phase removed and concentrated in vacuo. The final product was purified by distillation at 5 mm Hg and 176° C. The yield was 40%.
An infrared analysis of 3-quinuclidinol benzoate yielded the following bands:
2950, 1730, 1600 cm -1
Analysis by mass spectroscopy yielded the following:
227, 100, 137
N-methyl-3-quinuclidinyl benzoate was prepared by the addition of 0.013 moles of methyl iodide to 0.01 moles of 3-quinuclidyl benzoate.
EXAMPLE 10
DMAE And TMAE Cyclohexylcarboxylate
To 0.05 moles of dry dimethylaminoethanol in 100 ml of dry methylene chloride at room temperature was added slowly with stirring over a period of 15 min. 0.05 ml of cyclohexylcarboxyl chloride in 50 ml of methylene chloride. After another 30 min., the contents were extracted with H 2 O and the organic phase concentrated in vacuo. The final product was purified by distillation at 5 mm Hg and 176° C. The yield was 55%.
An infrared analysis of DMAE cyclohexylcarboxylate yielded the following bands:
2940, 1730, 1450, 1250, 1175
Analysis by mass spectroscopy yielded the following:
224, 170, 143, 97
TMAE cyclohexylcarboxylate was prepared by adding 0.013 moles of methyl iodide to 0.010 moles of DMAE cyclohexylcarboxylate in 50 ml of acetone and allowing the reaction to proceed overnight at room temperature. The white crystalline material was filtered, washed twice with 50 ml of ethyl ether and dried. The yield was 90%.
EXAMPLE 11
DMAE And TMAE Cyclopentylcarboxylate
To 0.05 moles of dry dimethylaminoethanol in 100 ml of dry methylene chloride at room temperature was added slowly with stirring over a period of 15 min. 0.05 ml of cyclopentylcarboxyl chloride in 50 ml of methylene chloride. After another 30 min., the contents were extracted with H 2 O and the organic phase concentrated in vacuo. The final product was purified by distillation at 5 mm Hg and 176° C. The yield was 55%.
An infrared analysis of DMAE cyclopentylcarboxylate yielded the following bands:
2940, 1730, 1450, 1170 cm -1
Analysis by mass spectroscopy yielded the following:
197, 154, 140, 127
TMAE cyclopentylcarboxylate was prepared by adding 0.013 moles of methyl iodide to 0.010 moles of DMAE cyclopentyllcarboxylate in 50 ml of acetone and allowing the reaction to proceed overnight at room temperature. The white crystalline material was filtered, washed twice with 50 ml of ethyl ether and dried. The yield was 90%.
The following examples are the protocols for the use of nicotinic agonists and antagonists for treating the tobacco habit of humans.
EXAMPLE 12
To aid a chronic smoker in discontinuing the tobacco habit, a 25 mg capsule of dimethylaminoethyl methylcarbamate HCl is administered orally 3 times daily for a period of 5-8 weeks.
EXAMPLE 13
In order to counteract the effects of nicotine and, thereby, diminish the desire for tobacco, a 25 mg tablet or capsule of dimethylaminoethyl cyclohexylcarboxylate HCl is given orally 3 times daily for a period of 5-8 weeks.
EXAMPLE 14
In order to counteract the effects of nicotine and, thereby, diminish the desire for tobacco, a 25 mg tablet or capsule of 3-quinuclidinyl benzoate is given orally 3 times daily for a period of 5-8 weeks.
EXAMPLE 15
In order to counteract the effects of nicotine and, thereby, diminish the desire for tobacco, a 25 mg tablet or capsule of dimethylaminoethyl benzoate is given orally 3 times daily for a period of 5-8 weeks.
EXAMPLE 16
The nicotine antagonist, α-lobeline HCl is administered orally in 2 mg capsules or tablets 3 times daily to treat the tobacco habit.
EXAMPLE 17
The nicotinic antagonist, benzoyl choline is used to counteract the cardiovascular and gastrointestinal disturbances due to the effects of nicotine in tobacco. The protocol consists of administering 10 mg capsules or tablets of the hydrochloride salt of benzoyl choline 3 times daily to a human being with a smoking habit.
EXAMPLE 18
The nicotinic antagonist, choline ester of cyclohexylcarboxylic acid is used to counteract the cardiovascular and gastrointestinal disturbances due to the effects of nicotine in tobacco. The protocol consists of administering orally 10 mg capsules or tablets of the choline ester of cyclohexylcarboxylic acid 3 times daily to a human being with a smoking habit.
EXAMPLE 19
The nicotinic antagonist, α-lobeline, is used to counteract the cardiovascular and gastrointestinal disturbances due to the effects of nicotine in tobacco. The protocol consists of administering orally 10 mg capsules or tablets of the hydrochloride salt of α-choline 3 times daily to a human being with a smoking habit.
EXAMPLE 20
Example 1 of U.S. Pat. No. 4,276,890 is repeated with the substitution of methylcarbamyl choline for the maltol and ethyl maltol to form troches.
EXAMPLE 21
Example 2 of U.S. Pat. No. 4,276,890 is repeated with the substitution of methylcarbamyl choline for the ethyl maltol to sticks of chewing gum. | Agonists and antagonists to nicotine are used as smoking deterrents.
The nicotinic antagonists have the following structural requirements:
(1) Aromatic, cycloalkyl, and heterocyclic carbamic acid esters of di- and trialkylaminoalkyl alcohols.
(2) Aromatic, cycloalkyl, and heterocyclic thiocarbamic acid esters of di- and trialkylaminoalkyl alcohols.
(3) Aromatic, cycloalkyl, and heterocyclic carboxylic acid esters of di- and trialkylaminoalkyl alcohols.
(4) Aromatic, cycloalkyl, and heterocyclic carboxylic acid esters of heterocyclic amino alcohols.
(5) Lobelia alkaloids: lobeline, lobelanine, and lobelanidine.
The nicotinic agonists (nicotine-like) have the following structural requirements:
(1) methylcarbamic acid esters of di- and trialkylaminoalkyl alcohols.
(2) methylthiocarbamic acid esters of di- and trialkylaminoalkyl alcohols. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods and apparatus for welding by use of high frequency electrical resistance heating and, more particularly, to the welding of the brake webs to brake tables to form brake shoes.
2. Description of the Prior Art
Traditionally, brake shoes have been formed by a series of projection welds between the brake table and the brake web. This has been accomplished by providing projections on a flate plate or table to concentrate the power flowing through the web. The web and the table are rolled together and resistance welded at the projections. The projections provide the metal that forms the weld to hold the brake shoe together. In the present invention, there are no projections. In the present invention, each brake web has a die break which can be defined as a small angular projection of metal which has been left by the die in the machine which stamps out the curved web pieces from flat metal plate. During welding the die brake melts and is forced into contact with heated metal of the brake table to provide most of the metal for the weld.
If one were to attempt to utilize the old method of resistance welding to form a continuous weld as is formed in the brake shoe of the present invention, two deleterious conditions would occur. First, the tremendous amount of heat required would melt so much of the web metal that the outer radius of the web would lose its shape thereby distorting the final brake shoe. In addition, the heat required would melt so much of the metal in the brake table that the thickness of the metal in the table under the web table interface would be greatly reduced. The combination of these two effects would result in a brake shoe that had a weaker web table weld interface than a brake shoe made by a series of projection welds of the same type.
By using a high voltage radio frequency current, a continuous weld of fused metal from the table and the web can be produced without any of the deleterious effects that occur in the prior art. Since the use of high frequency (200,000 Hz or more) versus the low frequency (60 Hz) prior art resistance welding brings about current densities in the order of 1 million watts per cubic inch at the weld point between the web and the table heating can be localized. When the localized heating is coupled with a rapid controlled advance of the weld point, the amount of fusion between the web and the table and the resultant melting thereof can be very closely controlled. The weld of the present invention uses only the die break on the web, which is about 0.017 inches, as the metal utilized for fusion. Therefore, the dimensions of both the table and the web remain relatively unchanged.
It is not desirable to use arc welding in making brake shoes since this requires fillet welds on either side of the web-table interface. These fillets (usually 3/16") may impinge on the rivet holes which are placed relatively close to the web to enable the braking material to be riveted on the brake shoe. Also, in a brake shoe with two webs, as is the case in the preferred embodiments discussed below, it is difficult to position two weld electrodes within the space between the two webs. In addition, the extra cost of slow weld speeds, weld wire and shield gas must be considered.
As will be better described below, the welds produced by the present invention are of superior strength when compared to the prior art resistance welding methods.
There are many examples of prior art devices which utilize radio frequency welding to form various continuous welds of strips and the like. U.S. Pat. No. 2,821,619, issued Jan. 28, 1958 to W. C. Rudd discloses the basic method of using high frequency electrical resistance to weld a continuous strip for a metal flange.
U.S. Pat. No. 3,513,284, issed May 19, 1970 to J. N. Snyder discloses an apparatus which uses high frequency resistance heating for welding an edge of a web member to the face of a flange member to form a long structural shape. This apparatus cannot be used for the welding of short sections as is the apparatus of the present invention.
U.S. Pat. No. 3,375,344, issued Mar. 26, 1968 to F. Kohler et al discloses a method and apparatus for simultaneously welding elongated metal members together at two spaced weld points using high frequency electrical current. Again, the apparatus disclosed is used to weld structural shapes out of long strips of metal and not short pieces as in the present invention.
U.S. Pat. No. 3,391,267, issued July 2, 1968 to W. C. Rudd also shows an apparatus for welding long strips to form structural shapes such as I beams. This patent also discloses a method of welding finite length flange sections to the web as long as the flange sections are in end to end contact. If this were not the case, as the patent points out, there would be weld interruptions or irregularities in the weld seam and a foot or more of the welded beam structure would have to be cut off and wasted where the trailing and leading ends of the successive strip pieces pass through the welding zone. In the present invention, the entire weld length may be no more than 14 inches and the method described below must be used to insure that a high quality weld is formed almost to the end of the brake table brake web interface.
SUMMARY OF THE INVENTION
It is an object of this invention to provide high frequency resistance heating apparatus which will efficiently concentrate heat along the weld path of a relatively short flange member to which is welded the edge of a relatively short curved web member.
Another object of this invention is to provide improved high frequency resistance heating apparatus which will permit the welding of brake shoes more rapidly than presently known brake shoe welding apparatus.
It is an additional object of this invention to provide a high frequency resistance heating apparatus which will efficiently concentrate heat along the weld path of a relatively short brake table to which is welded simultaneously the edges of two curved web member having a relatively short length.
It is a further object of this invention to provide a high frequency resistance welding apparatus and method which will permit the welding of relatively short flange and web pieces which produce a high quality weld almost to the end of the flange web interface.
It is yet another object of this invention to provide an automotive brake shoe having at least one web which has superior weld strenght at the web table interface compared to prior art resistance welded automotive brake shoes.
It is a still another object of this invention to provide a high frequency resistance welding apparatus which will simultaneously weld a brake table and a brake web to one another while simultaneously shaping the brake table to conform to the correct curvature required for the brake shoe.
It is yet another object of this invention to provide a high frequency welding apparatus in which the forces used to force the brake table into contact with an electrical conductor are transmitted mechanically through a pivoting arrangement to cause a second conductor to contact the brake web prior to welding.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of certain preferred embodiments thereof which in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a schematic of the automatic welding apparatus of the present invention;
FIG. 2 illustrates a brake web welded by the method and apparatus of the present invention;
FIG. 3 is an elevational view of the hold down method of the present invention;
FIG. 4 is an end on view of the apparatus of FIG. 3;
FIG. 5 is a cut away view of the brake shoes mounted on the fixture of FIG. 3 showing various positions of rotation of the fixture;
FIG. 6 is an elevational view of the apparatus for transferring electrical power to the brake shoes;
FIG. 7 is a isometric view of the preferred brake shoe of the present invention; and
FIG. 8 is a sectional view of the brake web of the present invention prior to welding.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a schematic view of the radio frequency welding system of the present invention which is generally denoted as 10. As indicated above, radio frequency welding systems are well known in the prior art. These welding systems generally consist of a radio frequency oscillator power supply 12 which feeds a radio frequency transformer 14 through primary conductors 16 and 18. Secondary conductors 20 and 22 convey the power from the transformer to the workpieces. In the present invention, the secondary conductors 20 and 22 are connected to both the brake web 24 and the brake table 26 respectively via a web ring contactor 27 and a table contactor 29.
Specifically, the conductors consist of a brake table conductor 22 which conducts power directly from the transformer to the table contactor 29 then to the brake table 26 and a web ring conductor 20 which conducts power to a web ring contactor 27 and then into a web contactor ring 28 which abuts the brake shoe web 24.
In the preferred embodiment, the radio frequency oscillator 12 and the radio frequency transformer 14 are situated in close proximity to minimize the length of the primary conductors 16 and 18. It has been found that power losses are greatly reduced if the length of the conductors 16 and 18 are kept at a minimum. Similarly, the location of the fixture for holding the brake web and the brake table for welding is located in close proximity to the radio frequency transformer 14 to minimize the length of the secondary conductors 20 and 22. In the preferred embodiment both the primary and secondary conductors are made of copper. Additional details of the secondary conductor will be described more fully below.
In the preferred embodiment, the oscillator 12 is a 150,000 kilowatt oscillator that converts 480 volt, 60 cycle alternating current to 1,300 volt, 300,000 cycle alternating current. The preferred frequency for operation will always be in the high frequency range between 200,000 cycles and 500,000 cycles.
The preferred brake table contactor 29 and the web ring 28 engage the brake shoe web 24 and the brake shoe table 26 after they have been located on a fixture 30. The fixture 30 has at least one slot 32 therein to receive and index the brake web 24. The fixture 30 also has a locating element 34 which stops the brake shoe table 26 when it is being fed onto the fixture and correctly positions it with respect to the brake web 24 to insure that the brake web and brake table are welded together in a proper position. In the preferred embodiment, the brake table 26 is initially flat although this is not necessary. The brake web, on the other hand, has a curvature equal to the desired curvature of the finished brake shoe. Thus, when the brake table and brake web and fed into the fixture such that one end of brake table 26 abuts one end of brake web 24, a diverging gap will be produced with its vertex at the abutting point between the brake table and the brake web. It is necessary to maintain a diverging gap during the welding operation since the power from the radio frequency oscillator will be concentrated at the vertex between the brake shoe table and web causing the heating thereof and consequent welding.
As can be seen in FIG. 3, a finger like hold down fixture 36 is provided. The hold down fixture 36 is positioned with respect to the contact area between web 24 and table 26 such that when welding is started and fixture 30 rotates in the direction marked A on FIG. 3, the hold down fixture provides initial deflection of the brake table to insure that after welding the finished brake shoe has the correct curvature. The hold down fixture 36 need be provided for only 2 or 3 inches beyond the weld point since by that distance the weld between the brake web 24 and the brake table 26 is strong enough after cooling to keep those two parts together. If the hold down fixture 36 were not provided, the weld would tear immediately after the brake web and brake table pass beyond the forge wheel 38. If two brake webs 24 are utilized, as is the case with the preferred brake shoe shown in FIG. 7, two hold down fixtures similar to that shown in FIG. 5 would be used and the hold down fixtures would be positioned along the brake table outboard of the webs.
In addition, FIG. 3 shows the support means for the forge wheel 38 and the hold down fixture 36. The support means consists of a frame 81 which may be mounted to the base of the support structure for the entire machine. A forge wheel support arm 82 is pivotally mounted to the support 81 to allow the forge wheel 38 to move in the vertical direction. The forge wheel 38 can be moved vertically up and down by a hydraulic system (not shown). The hold down fixture 36 is also pivotally mounted on the support structure 81. In the preferred embodiment, a bolt 84 is threaded through the arm 82 to contact the hold down fixture 36. The bolt 84 transmits the hydraulic force applied to forge wheel 38 to the hold down fixture 36 to insure clamping between the brake table 26 and the brake web 24. The bolt 84 may be adjusted in the vertical direction to insure proper engagement of the hold down fixture 36. A spring 86 is provided to lift the hold down fixture 36 out of engagement with the brake shoe when the forge wheel 38 moves in the vertical direction out of engagement with the brake shoe table 26.
FIG. 5 shows two brake shoes mounted on fixture 30. In the preferred embodiment, the method of welding the brake web 24 to the brake shoe table 26 involves automatically feeding the web and table onto the fixture 30, welding the two pieces together as fixture 30 rotates in the A direction and removing the finished brake shoe after welding is completed. As the weld ends on brake shoe 40 the fixture rotates slightly, as will be described below, to accommodate the loading of the brake web and brake table for brake shoe 42.
As can be seen in FIG. 5, the web 24 for brake shoe 40 is loaded onto the stationary fixture 30 when point one is at the arrow. The fixture 30 clamps the web 24 and then rotates so that point two is at the arrow and then the table 26 is fed in to stop 34. Rotation at this time is delayed until after the forge wheel 38 is lowered against the table 26. This action also forces it into contact with the contactor 29 at the end of the secondary conductor 20.
The power build up takes between 0.05 and 2 seconds until reaching the operating levels set forth above. On reaching the operating level, fixture 30 again begins to rotate so that a continuous forge weld is formed between the brake web 24 and the brake table 26. This welding continues until point three is at the arrow on FIG. 5 at which time the rotation of fixture 30 is stopped. In the preferred method of welding the brake web to the brake table, the power is maintained for a predetermined time, approximately 0.05 to 2 seconds, after fixture 30 has stopped rotating. After this time delay, the power is shut off and decays exponentially and, upon reaching a relatively low level after approximately 0.05 to 2 seconds, rotation of the fixture 30 again begins to where point four is at the arrow, the forge wheel is retracted and the web 24 and brake shoe 42 is loaded. After this time, the brake shoe 40 is removed from the fixture 30 while the fixture rotates between points four and five. Point five would be the point at which the table for brake shoe 42 is loaded and the point at which welding between the brake shoe web 24 and the brake table 26 and brake shoe 42 begins. The welding of the brake shoe 42 would continue until point six is at the arrow. The process would then be continually repeated as set forth above to enable the high speed welding of the brake shoes.
The above described method, including time delays, for welding the brake web 24 to the brake table 26 results in an excellent weld as close as approximately 1/2 inch from the end of the brake table. The prior art has mainly concerned itself of long structural shapes sch as "I" beams or tubing whereas the present invention teaches a method for welding relatively short finite parts with a typical embodiment having a weld of 16 inches. The length of the time delay must be accurately predetermined to insure the strength of the weld at the beginning and end of the finite length described above. A short time delay will cause a weak start on the weld. Too long a time delay will cause excessive melting of the web cross section which not only will produce a weak weld but also cause the metal to flow along the sides of the brake web and brake table interface which would cause drop like projections 25 shown in FIG. 2. These drop like projections, if extending along the brake table surface for too great a distance, would cause interference during other operations such as riveting the brake lining to the brake shoe. In the present invention, these drop like projections are minimized and extend no more than 1/8 inch along the brake table surface. This is well within the limits required to avoid interference during brake shoe lining assembly.
FIG. 6 provides a detailed view of the method for conducting power to the brake web 24 and the brake table 26. Power is conveyed from the high frequency transformer 14 through the secondary conductors 20 and 22. The secondary conductors 20 and 22 are composed of a first flexible portion 46 and 48 respectively and a second rigid portion 50 and 52 respectively. The rigid portions 50 and 52 are pivotally connected by a clamp support 54 which has two pivot points 56 and 58. The rigid conductor 50 pivots about point 56 and the rigid conductor 52 pivots about point 58. A spring 60 is positioned between rigid conductor 50 and 52 at an end thereof away from the welding area. The spring 60 acts to move the table contactor 29 which is attached to rigid conductor 52 into engagement with the table 26. The spring also moves the web ring contactor 27 which is attached to rigid conductor 50 into engagement with the web ring 28. The no load height adjustment screw 64 is provided to adjust the height of the table contactors 29 so that the table can feed over the contactors before the forge wheel is brought down. In addition, the adjustment screw provides a preload force therebetween the web ring and the web ring contactor. The force of table 26 against the table contactor 29 pivots contactor 52 around pivot point 58 pressing spring 60 which, in turn, pivots rigid conductor 50 about pivot point 56 forcing the web ring contactor 27 into engagement with the web ring 28 with greater force than achieved with the preload screw.
In the preferred embodiment, the web ring 28 contacts the brake shoe web over the entire radial length of the web. The web ring 28 rotates with fixture 30 as the web is rotated past the weld point between the web 24 and table 26. At any point after the loading of the webs onto fixture 30, the web ring contactor 28 is forced into positive electrical contact by pneumatic, mechanical or hydraulic means (not shown) located within fixture 30. A high contact force between the web ring 28 and the web 24 is required to insure no arcing between the contacting surfaces. This arcing may occur because of the lubricant film which is present on all of the electrical contact surfaces due to the design of the machine. It has been found that a contact force of 25 to 40 pounds per square inch between the contacts is required to insure no arcing between contacting surfaces. If arcing were to occur, the life of the electrical contacts would be substantially reduced. In addition, contact forces of between 25 and 40 pounds per square help overcome minor surface irregularities between the contacting surfaces which also would contribute to arcing problems.
The initial load between the web ring contactor 27 and the web ring 28 can vary between the slight gap, consequently no force, and 1/2 pound per square inch. As stated above, a pressure of between 25 and 40 pounds per square inch is required to insure positive electrical contact. Since the welding system described herein requires positive electrical contact to insure induction of electrical power without arcing, the term "contact" used herein denotes contact between conductors with a pressure of between 25 and 40 pounds per square inch rather than mere touching.
The flexible conductors 46 and 48 are tied into the rigid contactors 50 and 52 respectively in the area of the pivot points 56 and 58 which enables the use of flexible conductors which flex only about 2 degrees at the ends connected to the rigid conductors 50 and 52 while motion at the end of conductors 50 and 52 may be as much as 1/2 inch. In the preferred embodiment, layers of copper sheet soldered together at their ends are used to form flexible conductors 46 and 48. It should be noted that insulation (not shown) separates flexible conductors 46 and 48 and rigid conductors 50 and 52. This prevents arcing of power between the conductors and the resultant short circuit effects. In the preferred embodiment, the conductors are separated by sheets of Teflon, a registered trademark of the E. I. Dupont Company, approximately 1/8 inch thick. The Teflon insulation would be present at all points between the conductors. In addition, the clamp support 54 with its pivot points 56 and 58 is made out of a non electrically conductive material. In the preferred embodiment, the support assembly 54 is machined out of Delrin block.
FIGS. 2 and 7 show brake shoes 72 and 74 which are welded by the apparatus and method of the present invention. The only difference between FIGS. 2 and 7 is that FIG. 2 shows a brake shoe having one web 24 and FIG. 7 shows a brake shoe having two webs 78 and 80. In both cases, webs 24 are welded to the brake tables 26 by a continuous weld produced by radio frequency current. The above description deals mainly with the welding of one web to a brake table. If it is desired to weld two webs simultaneously to a brake table, the schematic of FIG. 2 would have to have a mirror image about the center line of the brake table 26. This would mean that a second set of oscillators, transformers, primary conductors, secondary conductors and table and web contactors would be required. One fixture 30 and one forge wheel 38 could be utilized to handle either one or two webs.
If two webs were desired, there would have to be two table contactors 29 each located outboard of its adjacent web. Two web ring contactors 27 and two web rings 28. would be required. The web ring 28 would also be located on the outboard side of each web 24. The web ring 28 could theoretically be located on the inside of the webs 24 except that in practice the room between the two webs is usually insufficient to permit insertion of two contactors.
In the preferred embodiment, the brake shoe webs 24 and the brake shoe tables 26 are fed onto fixture 30 automatically. This automatic feeder could be either air or hydraulically operated in that a pusher arm (not shown) would push each web into engagement with the web fixture 30 while a similar pusher arm would push the brake table 26 against the stop on the fixture 30. Due to the high voltage required and the high current densities involved in the above welding process, it would not be safe to feed the brake webs and brake tables by hand. The use of an automatic feeder and the indexing described above for making the radio frequency weld easily lends itself to electronic controls that enable the whole process to be fully automated. Thus, the apparatus of the present invention is able to produce far more brake shoes in a given time than were possible with several semi-automatic operated machines of the prior art. Specifically, an entire brake shoe can be loaded, welded and removed from the machine in 6 to 8 seconds.
Welds produced by the apparatus and method described above, being continuous, provide a far superior bonding between the brake web 24 and the brake table 26. Destructor tests run on brake shoes manufactured by the method of the present invention have failed by shearing the material of the brake table approximately 1/2 inch from the weld joint over the whole length of the weld. In contrast, brake shoes manufactured under the prior art resistance welding failed by shearing the weld at each of the projection welds. An additional advantage of a continuous weld is that no reinforcement arc welding of defective projection welds is necessary as was performed under the prior art when a poor weld was detected. This was done because one defective projection would substantially reduce the strength of the joint between the brake table and the brake web. The brake shoe of the present invention, having a continuous weld made with high voltage, high energy would not suffer from a defective weld in one small area. Surface impurities on the web or table decompose and are flushed out in the metal expulsion. The increased strength of the brake shoe produced by the present invention is due to the fact that 70 to 80% of the cross section of the web has fusion and this 70 to 80% continues for the entire weld length. To obtain the same effect in the area of the projection welds of the prior art, an excessive amount of weld heat would have had to been used.
An additional advantage of utilizing the high power density inherent with radio frequency welding is that the 70 to 80% weld across the thickness of the web is achieved without distorting the brake shoe table as much as the prior art. Th table stays flat along its width to within 0.020". Also, the prior art projection welded brake shoes had humps due to the welded projections which could not always be taken out by a "coining" operation.
FIG. 8 shows a cross section of the brake web 24 prior to the welding operation of the present invention. As is the case with most brake webs and brake tables, it has been stamped out of a flat plate which has a thickness in the preferred embodiment of about 0.320 inches. As can be seen from the figure, a die brake, or projection 66 remains after the stamping operation. In the prior art the die break would encourage misalignment of the table to the webs by causing the table projections to shift to the side before meeting. Utilizing a high frequency method of welding, the die brake acts to concentrate the current at the vertex between the brake web 24 and brake table 26 and further provide metal to form the weld between the brake web and the brake table. While the above welding method does not require a projection 66 for success, the die brake 66 enhances the weldability of the brake table and the brake web rather than being deleterious as it was in the prior art.
It will be apparent that the invention herein disclosed is well calculated to achieve the benefits and advantages hereinabove set forth, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the spirit hereof. | A method is provided for welding an edge surface of a curved metal brake shoe web to a metal brake shoe table. The brake shoe table surface has a greater radius of curvature than the brake shoe web prior to welding. The method consists of the steps of positioning the brake shoe table in longitudinal alignment with the brake shoe web with one end portion of the table surface abutting the brake shoe web surface over a predetermined distance and with the table surface diverging away from the brake shoe web edge to form a vertex where the surfaces abut. The abutting surfaces of the brake shoe web and the brake table are then pressed together at the vertex. The diverging surfaces of the brake shoe web and the brake table are contacted by separate electrodes. The high frequency alternating potential is then provided to each of the electrodes contacting the table and the web to induce a current to flow therebetween and thereby heat the interfacing surfaces in the area of the vertex. The brake shoe table and the brake shoe web are then rotated together along a curvelinear path while the pressure therebetween and the high frequency heating current applied thereto is maintained thereby welding the interfacing surfaces together. The rotation is stopped before the electrodes contacting the table traverse the other side of the diverging table surface and the alternating potential is allowed to reduce thereby allowing the high frequency heating current to dissipate. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 13/786,682, filed Mar. 6, 2013.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates generally to detonating cord, and more particularly to explosive assemblies formed from detonating cord, and further, to explosive assemblies forming a grid from detonating cord, and still further to a tool for forming such explosive assemblies.
[0004] 2. Description of the Problem and Related Art
[0005] The general concept of using detonating cord to make an explosive matrix as an explosive counter charge is well known, as exemplified by U.S. Pat. Nos. 2,455,354; 3,242,862; 4,768,417; 5,437,230; and 6,182,553; and by the U.S. Navy's Distributed Explosives Technology, described in “Distributed Explosive Technology (DET) Mine Clearance System (MCS) Ex 10 Mod 0 Program Life Cycle Cost Estimate for Milestone III” (Jun. 4, 1999). These prior designs were created for large military applications. Such applications require significant manpower and financial resources. These prior art explosive matrices must be manufactured well in advance of their usage. Field assembly is not practical because they are a complex of multiple lengths of detonating cords joined together. Moreover, due to cost, complexity and time of manufacturing, these prior art explosives matrices have been infeasible for commercial use as a blasting charge. In addition, these prior art explosive matrices are heavy and cumbersome to transport. They use rope or cord to hold the detonating cord together, creating undesirable bulk and weight.
[0006] Another shortcoming of these matrices results from the fact that detonating cord detonates linearly from the point of initiation, proceeding therefrom along the cord. Consequently, detonating cord can fail to propagate the detonation wave where the cord makes sharp turns, especially when large grain detonating cord is used. In some prior art designs, in order to assure sufficient transfer of the detonating wave between intersecting cords, clamps were used at all points of intersection of detonating cord. This adds further complexity and bulk to these prior art designs.
[0007] On the other hand, use of low grain non-propagating detonating cord is not always possible in prior art explosive matrices. Some prior art devices initiate at one point, in one direction, and use multiple lengths of detonating cord coupled together, which compromises reliability. To increase reliability, other explosive matrices incorporate multiple initiation points and multiple lengths of detonating cord, again making the design more complex and the assembly more complicated and expensive.
[0008] A later example that addressed many of these shortcomings is taught in U.S. Pat. No. 7,913,624 to the inventor hereof, wherein the explosive matrix assembly permits the construction of explosives counter charges which are more efficient, safer and less costly than the above mentioned prior art explosive matrices. It is typically assembled from a single length of detonating cord formed into a grid-like matrix pattern, and a small number of cable ties and or tape are required to force the detonating cord into 90 degree angles and to hold the assembly together. However, the detonating cord must be forced into position, which may be made easier with a field assembly tool, but the design of the field assembly tool sometimes creates less than perfect right angles throughout the matrix assembly. Furthermore, due to the geometric design of the grid, the matrix will always have intersections that consist of four over-laid sections of detonating cord, while two of the outer sides will always have three over-laid sections of detonating cord. This makes the charge non-uniform.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
[0010] FIG. 1 illustrates two options for an exemplary embodiment of an explosive matrix assembly using a single length of detonating cords as disclosed herein;
[0011] FIG. 2 illustrates an exemplary embodiment in which two or more explosive matrix assemblies may be fastened together;
[0012] FIG. 3 depicts a one side member of an exemplary tool useful for forming an explosive matrix assembly as disclosed herein;
[0013] FIG. 3A is an end view of an exemplary side member comprising two identical members slidingly engaged with one another;
[0014] FIG. 4 depicts assembly of an exemplary tool useful for forming an explosive matrix assembly as disclosed herein;
[0015] FIG. 5 depicts an exemplary side member comprising two slidingly engaged members showing an exemplary embodiment of an adjustably extendable side member;
[0016] FIG. 6 depicts assembly of an exemplary tool useful for forming an explosive matrix assembly as disclosed herein comprised of the exemplary side members for FIG. 5 ;
[0017] FIG. 7 depicts another exemplary embodiment of an explosive matrix assembly as disclosed herein;
[0018] FIG. 8 depicts yet another exemplary embodiment an explosive matrix assembly as disclosed herein;
[0019] FIG. 9 is a perspective view of the embodiment depicted in FIG. 8 ;
[0020] FIG. 10 shows another exemplary embodiment of an explosive matrix assembly as disclosed herein;
[0021] FIG. 11 illustrates yet another exemplary embodiment of the explosive matrix assembly as disclosed herein.
DETAILED DESCRIPTION
[0022] The various embodiments of the disclosed explosive matrix and their advantages are best understood by referring to FIGS. 1 through 11 of the drawings. The elements of the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention. Throughout the drawings, like numerals are used for like and corresponding parts of the various drawings.
[0023] Furthermore, reference in the specification to “an embodiment,” “one embodiment,” “various embodiments,” or any variant thereof means that a particular feature or aspect described in conjunction with the particular embodiment is included in at least one embodiment. Thus, the appearance of the phrases “in one embodiment,” “in another embodiment,” or variations thereof in various places throughout the specification are not necessarily all referring to its respective embodiment.
[0024] This invention may be provided in other specific forms and embodiments without departing from the essential characteristics as described herein. The embodiments described above are to be considered in all aspects as illustrative only and not restrictive in any manner. The following claims rather than the description below indicate the scope of the invention.
[0025] Referring to the drawings, FIG. 1 depicts a preferred embodiment of the explosive matrix assembly 1 . The explosive charge is provided by a single length of detonating cord 2 that is configured into a first set of at least three parallel straight portions 3 lying in a first plane. There are equal spaces 4 , which can altered in size depending upon the desired size of the overall matrix assembly, but will always be equal to each other within the same explosives matrix assembly, separating the straight portions from each other. The detonating cord is further configured so that there is a second set of at least three more parallel straight portions 5 that are perpendicular to the first set and lying in a second plane. The second set of straight portions 5 are spaced in a manner similar to the first set of straight portions 3 . At one end of each parallel straight portions 3 , 5 of detonating cord, there is a looped portion 11 .
[0026] In one embodiment, the detonating cord 2 is further configured so that two ends of the detonating cord, 6 a and 6 b, are fastened together with ties or tape 7 to form a closed loop 8 , or as depicted in Option 2 , looped back such that the ends 6 a and 6 b meet and abut one another. This arrangement may be secured with sheet tape or polyethylene foam sheets 22 , as depicted in FIG. 7 secures the closed loop.
[0027] The explosive initiator 9 can be attached to the detonating cord 2 at any point within the explosives matrix assembly 1 . In a preferred embodiment, each of the first and second sets comprises an odd number of parallel straight portions 3 , 5 . The reason for the odd number of parallel straight portions is so that a single looped portion 10 of detonating cord may run between the two sets of parallel detonating cords at a point that is diagonally across from the looped ends 6 a and 6 b that are secured to each other.
[0028] Typically, the perimeter of each explosive matrix assembly 1 roughly defines a rectangular panel, the maximum size of which may be made according to the intended function, the minimum size dependent upon the limited flexibility of detonating cord 2 . Alternatively, in the event a larger explosive matrix 1 is desired, assembly panels may be joined together. For example, if the explosive matrix must cover a larger surface area, two or more explosive matrix assemblies are secured to one another by cable ties 12 , as depicted in FIG. 2 . All explosive matrix assembly panels 1 are secured to one another can be initiated by the same initiator as would be appreciated by those skilled in the relevant arts.
[0029] The first step in deploying the claimed invention is for the explosives technician to decide how large an explosive matrix 1 area is needed to completely cover the surface area required. If the surface area required is greater than the surface area of a single explosives matrix assembly 1 , a sufficient number of explosive matrix assembly panels 1 may be made and secured to one another by additional cable ties 12 as depicted in FIG. 2 .
[0030] The explosives technician determines the N.E.W. of the counter charge needed to perform the explosives work required. The N.E.W. of the matrix charge is based on the area of the matrix charge and detonating cord grain weight. Charts or diagrams may be prepared to provide users of the matrix tool detailed information on the assembly of the matrix charge, the amount of detonating cord needed for a specific size matrix charge, and the N.E.W. for the matrix charge based on the grains per foot of detonating cord and the areal size of the matrix charge.
[0031] In order to quickly and conveniently assemble the explosive matrix 1 in the field, an assembly tool 21 may be provided, as shown in FIGS. 3 through 6 . The assembly tool 21 is designed so that it may be carried disassembled to the place where it will be used to deploy the matrix 1 . An exemplary assembly tool 21 may include four or eight substantially identical side members 13 , an example of which is illustrated in FIG. 3 . In the illustrated embodiment, each of the side members 13 comprises an elongated member having at least one castellated edge 28 along a long edge defining a set of recesses 15 and interstitial tabs 22 . The castellated edge 28 should define at least three, and preferably six, or more recesses 15 , each of which are dimensioned to receive and engage detonating cord and accommodate the diameter of the cord.
[0032] In the illustrated embodiment, the side member 13 terminates in a protrusion 16 extending from one end 30 , with the opposing end 31 including a cut-out 17 defined perpendicularly to the long axis of the side member 13 . The cut-out 17 is dimensioned to snugly receive the protrusion 16 comprised in a second side member 13 . Bore holes 29 a are defined through the protrusion 16 and corresponding bore holes 29 b, are defined in the walls defining the cut-out with the end most holes opening to the outer end of the member 13 . As illustrated in FIG. 4 , the tool 21 may be assembled by fitting the protrusion 16 of a first member 13 into the cut-out 17 of another such that the corresponding bore holes 29 a, 29 b align. Fastener pins 14 may then be inserted into the aligned bore holes 29 a, 29 b from the open outer thereof, thus fastening one end of one member with a counterpart end of a second member, forming a right angle. Assembly of the members 13 is repeated in this manner until a generally rectangular loom results with the castellated edges oriented away from the center of the tool shape. See FIG. 4 . It will be appreciated that the ends of the members 13 may be fastened together in any suitable manner to form a secure perpendicular connection, including lap joints, hinged couplings, etc. Additionally, although bore holes 29 a, 29 b are depicted in the exemplary embodiment in corresponding pairs, more or less holes may be used.
[0033] In another embodiment, each side member 13 may comprise two parallel side members, 13 a, 13 b slidingly engaged with one another with their corresponding castellated edges 28 oriented in the same direction. The sliding attachment of the two members 13 may be accomplished by any suitable means known in the art. For example, with reference to FIG. 3A , one member 13 is paired with another member 13 , using a sliding dovetail joint 18 to form a sliding pairs 20 with one member 13 a having an elongated dovetail slot 18 a lengthwise defined in a planar surface and the second member 13 b having an elongated dovetail pin 18 b extending from the opposing surface thereof. As depicted in FIGS. 5 , and 6 , the sliding pairs 19 may be assembled in the manner described earlier creating an adjustable assembly tool 21 facilitating the formation larger explosives matrix assemblies.
[0034] Once the matrix tool 21 is assembled it may be used to assemble the explosive matrix 1 , by weaving a length of detonating cord 2 on the tool by inserting the cord into a first recess 15 , stretching the cord across the tool and inserting the cord 2 into an opposite second recess 15 , bending the cord around the adjacent interstitial tab 22 to insert into a third recess 15 adjacent the tab 22 , and so on until the form depicted in FIG. 1 is complete. The matrix 1 grid is complete with end 6 b back at the starting point.
[0035] Once the grid is complete, ties or tape 7 are used to hold ends 6 a and 6 b together in a closed loop 8 , or abutted together and secured with adhesive sheet tape, or, for example, polyethylene foam sheets 23 with one surface coated with an adhesive which is place on either side of the grid and then pressed together to bond the grid 1 and sheets 23 together, as shown in FIG. 7 .
[0036] The tool may be removed from the completed matrix assembly 1 by removing the fasteners 14 allowing the matrix assembly 1 to slide off the assembly tool.
[0037] In yet another alternative embodiment, the explosives matrix assembly 1 may be combined with a plurality of point explosives 24 , such as sheet explosives, as shown in FIG. 8 and FIG. 9 . The explosives matrix assembly 1 only needs to be of sufficient strength to initiate the point explosives 24 . Because the point explosives 24 are the effective explosives charge, not the explosives matrix assembly 1 , a lower grain of cord 2 may be used. Using the matrix assembly 1 , point explosives 24 are placed at the points in the matrix assembly 1 where lengths of detonating cord 2 cross. Initiation of the detonating cord 2 will result in substantially simultaneous initiation of the the point explosives 24 creating a shotgun effect with the point explosives 24 . Thickness, weight, size, and type of the point explosives 24 may vary depending upon the needs of the explosives work to be done.
[0038] Yet another embodiment employs the explosives matrix assembly 1 to initiate insensitive blasting agents 25 , such as ANFO (Ammonium Nitrate and Fuel Oil) in place of primers, as shown in FIG. 10 . By using the explosives matrix assembly 1 to initiate the blasting agents 25 , the critical diameter of the blasting agent 25 can be reduced below its normally accepted critical diameter without a low order detonation. If a greater surface area of the charges is desired or required, matrix assembly 1 panels may be connected together using cable ties or tape 12 , as described above. All explosive charges so secured to one another can be initiated by the same explosives initiator 9 .
[0039] In a further embodiment and with reference to FIG. 11 , the explosives matrix assembly 1 e may be connected with other matrix assemblies 1 j, e.g., attaching at least three panels, and preferably five or six panels, in a mutually perpendicular shape, i.e., a cube 27 , advantageous as an explosives device 26 disruption charge (render safe) to defeat electronic switches and power sources, as shown in FIG. 11 . A low energy detonating cord 2 may be employed in this example. The explosives device 26 is either placed in the cube 27 or the cube 27 is placed over the explosives device . All explosive matrix assemblies 1 so secured to one another can be initiated by the same explosives initiator 9 .
[0040] As described above and shown in the associated drawings, the present invention comprises an explosive matrix assembly. While particular embodiments of the invention have been described, it will be understood, however, that the invention is not limited thereto, since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is, therefore, contemplated by the appended claims to cover any such modifications that incorporate those features or those improvements that embody the spirit and scope of the assembly. | An explosive matrix includes a grid structure formed from a single length of detonating cord with one set of spaced-apart detonating cord sections lying in one plane that perpendicularly overlays a second set of spaced-apart sections lying in a second plane such that at each section crossing location the crossing consists of no more than two perpendicular sections of detonating cord. A tool for forming the matrix includes a frame comprising four side members, each having identical castellated edges in which are defined a plurality of notches for receiving a section of detonating cord. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 176,236, filed Aug. 8, 1980, now abandoned, which in turn is a continuation of Ser. No. 940,681, filed Sept. 8, 1978, now abandoned, which in turn is a continuation-in-part of Ser. No. 919,590, filed June 27, 1978, now abandoned.
BACKGROUND OF THE INVENTION
The present invention is concerned with processes for preparing epihalohydrin enantiomers and intermediates.
Epibromohydrin enantiomers have been prepared by a resolution process--and an epichlorohydrin enantiomer has been prepared from 1-bromo-3-chloropropan-2-ol enantiomer derived from the epibromohydrin [Chemische Berichte 48, 1862-184, (1915)].
An improved method for preparing the epihalohydrin enantiomers from sulfonyloxyhaloalcohol has been discovered--and an improved process for preparing an intermediate useful in the synthesis has also been discovered.
SUMMARY OF THE INVENTION
Process for (a) preparing (S) or (R) epihalohydrin from an (S) or (R) sulfonyloxyhaloalcohol and (b) preparing (S) glycerol-1,2-acetonide from isopropylidine-D-mannitol.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention is a process for preparing an enantiomer of eiphalohydrin which comprises treating an enantiomer of an alcohol having the formula ##STR1## wherein Z is phenyl, monosubstituted phenyl, CF 3 or C 1 -C 6 alkyl and X is Cl or Br with an alkali metal glycolate and recovering said epihalohydrin by distillation.
The reaction is illustrated by the following equation: ##STR2## The product is recovered in good yield by direct vacuum distillation at room temperature from the reaction mixture.
Z may be phenyl, monosubstituted phenyl or C 1 -C 6 alkyl. The monosubstituted phenyl group is exemplified by C 1 -C 3 -alkylphenyl, e.g., p-propyl-phenyl, o-methylphenyl, and m-ethylphenyl, p-NO 2 -phenyl, p-OCH 3 -phenyl, 2-chlorophenyl and the like. The C 1 -C 6 alkyl group includes CH 3 , C(CH 3 ) 3 , isopropyl, n-hexyl and the like. The p-methylphenyl and CH 3 groups are preferred.
The alkali metal glycolate includes K or Na ethylene glycolate, with Na ethylene glycolate being preferred.
When a more conventional low boiling solvent/strong base, e.g., methanol/NaOCH 3 is used in place of the glycolate in reaction (I 1 ), the product yield obtained on direct vacuum distillation at room temperature is low.
Another embodiment of the present invention is a process for preparing (S)-glycerol-1,2-acetonide of the formula ##STR3## which comprises (a) treating 1,2:5,6-di-O-isopropylidine-D-mannitol having the formula ##STR4## with lead tetracetate in a suitable solvent and (b) reducing the reaction product from (a) with alkali metal borohydride and (c) treating the reaction mixture from (b) with an ammonium halide.
Suitable solvents include aprotic compounds such as tetrahydrofuran (THF), ethylacetate, dimethylformamide (DMF) and the like. THF and ethylacetate are preferred solvents.
Ammonium halides include NH 4 Br and NH 4 Cl. NH 4 Cl is preferred.
The reaction of (B) with Pb(OAc) 4 in step (a) may be carried out at any convenient temperature. Temperatures below about 10° C. are preferred. The preferred molar nature of lead tetraacetate to (B) is about 1:1.
The reduction of the step (b) is also carried out at a convenient temperature. Preferred temperatures are below about 10° C. The NaBH 4 reducing agent is generally added to the reaction mixture in solution e.g., in aqueous NaOH. The amount of NaBH 4 may be varied. It is preferred that about 2 moles of NaBH 4 per mole of (B) reactant be used.
The reaction of step (b) is allowed to proceed for a period sufficient for the reaction to be complete, e.g., for about 30 minutes at about 0° C. and for about 90 minutes at room temperature. At the appropriate time, NH 4 Cl is added to solution until the pH reaches about 8. After the reaction solvent is removed under reduced pressure, the product (A) is recovered using conventional procedures.
When sodium periodate [Synthesis 423 (1977); Biochemistry 3, 976 (1964)] is used in place of Pb(OAc) 4 the product obtained is generally racemic.
When H 2 /Raney nickel [J. Biol. Hem. 128, 463 (1939)] is used in place of the NaBH 4 , yields obtained are variable depending on the quality of the Raney nickel.
The formula (A) glycerol is especially useful as an intermediate in the preparation of (S) and (R) epihalohydrins. The following flow sheet illustrates this utility: ##STR5##
Reactions related to 1 and 2 are dislosed in J.A.C.S. 64, 1291 (1942). Reaction 3 is related to that described in Tetrahedron Letters, 4361 (1969). Reaction sequence 5 and 6 has been carried out with racemic reactants [Bull. Chem. Soc. Japan 39, 413 (1966)].
The preparation illustrated by the flow sheet shows that either the (S) or (R) enantiomer of an epihalohydrin, especially epichlorohydrin, can be prepared directly from a common starting material [compound (A) or product (B)] without requiring costly and inefficient resolution procedures. This constitutes another aspect of the present invention.
Epihalohydrins have wide utility in organic synthesis. The enantiomers of epihalohydrin may be especially useful to prepare intermediates which in turn can be used to prepare specific isomers which have pharmaceutical utility. One such preparation is illustrated by the following reaction equations: ##STR6## The product (C) is a commercial β-adrenergic blocking agent.
Other preparations utilizing the Step 1, sequence A type reaction are illustrated by the following reaction equation: ##STR7## X in this equation is H, CHO, CN or OCH 3 .
Where a stronger base, such as NaH in DMF, is used in the above reactions, the intermediate (C or C 1 ) is obtained as a mixture of (S) and (R) isomer.
Another aspect of the present invention relates to the novel sulfonyl intermediates of the type obtained in Step (5) in the above flow sheet. These compounds are represented by the formula ##STR8## where L may be an alkyl group such as CH 3 , C 4 H 9 , CF 3 -- and the like, or a phenyl group such as phenyl, p-chlorohydrin, p-tolyl, n-nitrophenyl and the like.
The formula (E) compounds are useful as intermediates in reactions related to Reactions A and B as illustrated by the following equation: ##STR9## aryl includes groups such as phenyl, ##STR10## where X is a substituent such as chloro, CHO, CN, C 1 -C 4 alkoxy and the like; pyridyl, cyanopyridyl 4-morpholino-1,2,5-thiadiazolyl and the like.
When an enantiomer i.e., (R) or (S) isomer, of the (E) compound is used in the reaction, the type of base and the L group have an effect on the isomer configuration of the final product. Illustrating this effect are the following two equations: ##STR11## Thus, where L is CF 3 and a strong base is used, the (S) isomer of the formula (E) compounds yields the (S) isomer of the formula (G) compound. Therefore, by utilizing an enantiomer of 3-trifloxy-1,2-epoxypropane and a suitable base in the (C) reaction the isomeric configuration of the trifloxy enantiomer is maintained in the product. If an enantiomer of mesyloxy mesyloxyepoxypropane is used, a mixture of enantiomers is obtained.
The following example describes the preparation of (S)-3-trifloxy-1,2-epoxypropane. All temperatures are in °C.
EXAMPLE A
To pyridine (10.3 g, 0.13 m) in CH 2 Cl 2 (300 ml) cooled to -23° in a dry ice/CCl 4 bath was added trifluoromethanesulfonic anhydride (36.7 g, 0.13 m) in CH 2 Cl 2 (100 ml) dropwise over 1/2 hour. While still cooling this mixture at -23°, (R)-glycidol (8.6 g, 0.116 m) in CH 2 Cl 2 (100 ml) was added dropwise over 1/2 hour. After stirring for 5 minutes with cooling and 15 minutes without, an equal volume of hexane was added and the solids were filtered. Concentration of the solution at 30°/25 torr. left a residue which was distilled to give (S)-3-trifloxy-1,2-epoxypropane (40%); bp 35°-39°/0.2 mm; [α] D 24 =14.7° (c=3.90, CHCl 3 ); 1H NMR (CDCl 3 ) 4.8 (1H, d of d, J=11, J=3 ), 4.4 (1H, d of d, J=11, J=3), 3.3 (1H, m), 2.9 (1H, t, J=4.5), 2.7 (1H, J=4.5, J=2).
The following examples illustrate the processes of the present invention. All temperatures are in °C.
EXAMPLE 1
(S)-Glycerol-1,2-acetonide
To an ice-cooled solution of 1,2:5,6-di-O-isopropylidine-D-mannitol (80.0 g, 0.3 ml) in THF (400 m) was added portionwise with stirring dry Pb(OAc) 4 (134 g, 0.3 m), while maintaining the temperature below 10° C. The solution was stirred for 30 minutes with ice cooling and an additional 30 minutes without. After filtering through Super-Cel and cooling in an ice bath, a solution of NaBH 4 (22.9 g, 0.62 m) in 4% aqueous NaOH (400 ml) was added dropwise with vigorous stirring while maintaining the temperature below 10° C. After stirring in an ice bath for 30 minutes and at room temperature for 90 minutes, solid ammonium chloride was added to the solution until it buffered at about pH 8. The THF was removed under reduced pressure, and the resulting aqueous solution was saturated with NaCl. After extracting into ethyl acetate, the organic layer was washed with 5% aqueous NaOH saturated with NaCl, dried (Na 2 SO 4 ), and concentrated. Distillation afforded pure (S)-glycerol-1,2-acetonide (58.4 g, 73%); bp 80°-90° C./20 mm; 1 H NMR (CDCl 3 ) 1.45 (6H, s), 3.5-4.5 (6H, m); [α] D 25 =11.3° (c=5.174, CH 3 OH).
EXAMPLE 2
(a) (R)-3-Tosyloxy-1,2-propanediol
To an ice-cooled solution of (S)-glycerol-1,2-acetonide (72.0 g, 0.55 m) in pyridine (300 ml) was added portionwise with stirring p-toluenesulfonyl chloride (104.0 g, 0.55 m). After standing in a refrigerator for 16 hours, the reaction mixture was diluted with ether (300 ml), washed with 1 N HCl until the aqueous wash was acidic, and then washed with saturated aqueous NaHCO 3 . The ether layer was dried (Na 2 SO 4 ) and concentrated to give (R)-3-tosyloxypropanediol acetonide (141.0 g, 91%), which was used without further purification.
The acetonide from above in acetone (100 ml) and 1 N HCl (300 ml) was heated on a steam bath for 30 minutes. The resulting solution was concentrated to dryness, and the residue was dissolved in CH 2 Cl 2 . After drying (Na 2 SO 4 ) and concentration, the resulting oil solidified upon standing. Residual solvents were removed at 25° C. and 0.5 mm over 18 hours to give (R)-3-tosyloxy-1,2-propanediol, (121.0 g, 100%); mp 54°-59° C. (lit=61°-63° C.); 1 H NMR (CDCl 3 ) 2.4 (3H, s), 3.3-4.3 (7H, m), 7.35 and 7.8 (4H, 2d, J=8).
(b) (R)-Glycidol
To an ice-cooled solution of (R)-3-tosyloxy-1,2-propanediol (120.5 g, 0.49 m) in methanol (200 ml) and ether (100 ml) was added sodium pellets (10.7 g, 0.45 m) in three portions over approximately 1 hour, Stirring was continued with ice cooling for 1 hour. The reaction mixture was concentrated at 30° C., and the residue was taken up in ether. After filtration, the solvent was removed at 30° C./25 mm, and the residue was treated with chloroform and reconcentrated to remove the last traces of methanol. An additional chloroform treatment as above gave (R)-glycidol (33.5 g, 93%), which was used without purification in subsequent steps.
(c) (S)-3-Mesyloxy-1,2-epoxypropane
To an ice-cooled solution of (R)-glycidol (5.0 g, 0.068 m) and triethylamine (8.1 g, 0.080 m) in toluene (100 ml) was added, over 15 minutes, methanesulfonyl chloride (8.0 g, 0.070 m) in toluene (25 ml). Stirring was continued with cooling for 1 hour. The solution was filtered and concentrated to give an 80-85% yield of the crude (S)-3-mesyloxy-1,2-epoxypropane; this material could be used without further purification. Distillation gave 7 (61%); bp 92°-95° C./0.1 mm; [α] D 22 =23.7° (c=5.16, CH 3 OH); 1 H NMR (CDCl 3 ) 4.5 (1H, d of d, J=12, J=3), 4.1 (1H, d of d, J=12, J=6), 3.3 (1H, m), 3.1 (3H, s), 2.8 (2H, m).
(d) (R)-Epichlorohydrin
Concentrated HCl (20 ml) was added to (S)-3-mesyloxy-1,2-epoxypropane (5.0 g, 0.033 m) over 15-20 minutes. After stirring for an additional 30 minutes, the water was removed through the addition and subsequent evaporation of ethanol. Finally, residual ethanol was removed at room temperature and 0.1 mm to give (R)-3-mesyloxy-2-hydroxy-1-chloropropane, (5.4 g, 85%); 1 H NMR (CDCl 3 ) 4.35 (2H, d), 4.1 (1H, m), 3.65 (2H, d), 3.1 (3H, s), 2.9 (1H, broad s); [α] D 22 =7.1° (c=5.78, CH 3 OH).
To (R)-3-mesyloxy-2-hydroxy-1-chloropropane (5.4 g, 0.029 m) in dry ethylene glycol (20 ml) was added a solution of sodium ethylene glycolate [from sodium pellets (0.8 g, 0.034 ml)] in dry ethylene glycol (20 ml). After stirring for 15 minutes, (R)-epichlorohydrin (2.2 g, 86%) was distilled from the reaction mixture at room temperature and 0.2 mm and trapped in dry ice/acetone; 1 H NMR (CDCl 3 ) & 3.6 (2H, d), 3.2 (1H, m), 2.8 (2H, m); [α] D 22 =33.0° (c=4.22, CH 3 OH).
A small sample was further purified by preparative GC on an HP 5710 A instrument using a 6' 5% OV-17 column with an oven temperature of 60° C. to give (R)-epichlorohydrin; [α] D 23 =34.3° (c=1.50, CH 3 OH).
EXAMPLE 3
(S)-Epichlorohydrin
To triphenylphosphine (13.2 g, 0.05 m) in CCl 4 (20 ml) and DMF (50 ml), (R)-3-tosyloxy-1,2-propanediol (12.3 g, 0.05 m) in DMF (50 ml) was added all at once. After the addition was complete, the temperature increased to 50° C. over 15 minutes. The mixture was then allowed to stir for 3 hours. The residual solvents were removed (50° C., 2 mm) and the residue was taken up in H 2 O, dried (Na 2 SO 4 ), and concentrated. Residual solvents were removed at 25° C. and 0.2 mm over 18 hours.
To this residue, composed of triphenylphosphine oxide and (S)-3-tosyloxy-2-hydroxy-1-chloropropane, in dry ethylene glycol (50 ml) was added a solution of sodium ethylene glycolate [from sodium pellets (1.25 g, 0.054 m)] in dry ethylene glycol (50 ml). After stirring for 15 minutes, (S)-epichlorohydrin was distilled from the reaction mixture at room temperature and 0.2 mm and trapped in dry ice/acetone. The 1 H NMR indicated that traces of CH 2 Cl 2 and H 2 O were present; [α] D 20 =28.1° (c=2.47, CH 3 OH).
A small sample was purified by preparative GC to yield pure (S)-epichlorohydrin [α] D 23 =33.0° (c=2.47, CH 3 OH).
Analogous epibromohydrins are obtained when the corresponding bromo reactants replace the chloro reactants in Examples 2 and 3.
The following examples illustrate low yields obtained when low boiling solvent/strong base systems are used instead of the glycolate system of the present invention, e.g., Example 2(d) or Example 3. All temperatures are in °C.
EXAMPLE 4
Epichlorohydrin
Concentrated HCl (20 ml) was added to 3-mesyloxy-1,2-epoxypropane (5.0 g, 0.033 m) over 15-20 minutes. After stirring for an additional 30 minutes, the water was removed through the addition and subsequent evaporation of ethanol. Finally, residual ethanol was removed at room temperature and 0.1 mm to give 3-mesyloxy-2-hydroxy-1-chloropropane (5.4 g, 85%).
To 0.95 g (0.005 m) of this crude mesylate was added NaH (0.25 g, 50% oil dispersion, 0.005 m). After stirring for 30 minutes, the mixture was filtered and the solvent was removed on a rotary evaporator at 30°/25 mm to give epichlorohydrin (0.20 g, 43%). The proton NMR of this compound indicated the presence of some (˜10%) of the corresponding 3-mesyloxy-1,2-epoxypropane.
Several other reactions of the Example 4 type were run in order to probe the effectiveness of various base/solvent combinations. Although the use of NaH/CH 3 OD for an NMR study indicated essentially quantitative production of epichlorohydrin, none of the other base/solvent combinations (see table below) gave better yields than the 43% in Example 4.
TABLE______________________________________ Crude Yield ofBase/Solvent Epichlorohydrin______________________________________NaH/ether 20%NaH/THF noneNaH/CH.sub.2 Cl.sub.2 40%n-BuLi/ether-hexane 30%aqueous NaOH/H.sub.2 O--ether none______________________________________
EXAMPLE 5
(R)-Epichlorohydrin
Concentrated HCl (75 ml) was added to (S)-3-mesyloxy-1,2-epoxypropane (6.8 g, 0.045 m). After stirring for 30 minutes, the water was removed through the addition and subsequent evaporation of ethanol. Finally, the residual ethanol was removed at room temperature and 0.1 mm to give (R)-3-mesyloxy-2-hydroxy-1-chloropropane (7.8 g, 92%). This material was dissolved in ether (50 ml) and methanol (10 ml) in an ice bath and sodium (0.94 g, 0.041 m) was added. After stirring for one hour, the mixture was filtered and concentrated at 30°/25 mm. Added acetone, filtered and reconcentrated at 30°/25 mm. Attempted distillation of the residue led to total decomposition; none of the desired (R)-epichlorohydrin was obtained.
Claims to the invention follow. | Processes for preparing (S) or (R) epihalohydrin and an (S) substituted glycerol intermediate are disclosed. | 8 |
FIELD OF THE INVENTION
A scalable energy efficient method and system for processing wastewater to separate, extract and recover hydrocarbons and to filter and treat the associated water to enable; re-use for industrial purposes, or re-use for agricultural purposes or environmentally sustainable discharge.
BACKGROUND OF THE INVENTION
In the hydrocarbon extraction industry categories of contaminated water requiring treatment include surface wastewater; originating from precipitation and groundwater sources, produced water; recovered from underground with associated hydrocarbons, and process water; introduced during hydrocarbon production techniques. Hydrocarbon production techniques which use large quantities of water include; Cyclic Steam Stimulation (CSS) for heavy oil production, Steam Assisted Gravity Drainage (SAGD) for oilsand bitumen production, Water Flooding for conventional oil reservoir production and hydraulic fracturing for unconventional gas and oil production. These forms of wastewater typically include a number of individual components namely, water, hydrocarbons, suspended solids, and contaminants which include but are not limited to, dissolved solids, naturally occurring compounds and synthetic additives.
Current industrial practices include disposing of contaminated wastewater into deep underground disposal wells, impoundment and various treatment technologies. Compliance with increasingly stringent environmental regulations requires improved processes to separate and extract the hydrocarbons, solids and contaminants and process the water to a purity suitable for re-use for industrial purposes, or potentially to a significantly enhanced purity suitable for re-use for agricultural purposes or environmentally sustainable discharge.
Various surfactants, filters and chemical additives have been developed for extracting hydrocarbons from wastewater. One example is membrane bioreactors which have been also proposed for use in hydrocarbon removal from industrial wastewater. In the known arrangements, the reactors employ hollow fibre membranes. The reactors typically employ microfiltration hollow fibres which are submerged in the bioreactor.
In U.S. Pat. No. 6,521,125, there is disclosed an oil/hydrocarbon removal system. It is indicated in the disclosure that the system is useful for collecting the bilge of marine vessels which assists in ensuring that there is oil-free water in the surrounding water of the vessels. The filter in the medium is indicated to comprise a mixture of peat, anthracite and bentonite to produce a composition that is both hydrophobic and oleophilic.
In many instances, in the individual arrangements discussed above, the filter technology requires the replacement of the filter material which is eventually prone to plugging and general wear or reduced effectiveness. This presents difficulties in a remote location where accessibility of replacement parts is challenging, if not impossible. Further, many of the technologies are particularly effective as filters for removing the hydrocarbons, however, in many situations the water which must be discharged or otherwise handled is not properly decontaminated in compliance with stringent environmental restrictions.
Particularly in the case of produced water, there are typically high levels of dissolved solids and salts, and therefore desalination treatment may also be required prior to re-use or discharge.
Reverse osmosis membranes are the most prevalent desalination treatment for large volumes of water. However, even minimal levels of hydrocarbons in the input fluid stream will cause fouling, resulting in impaired functionality and deterioration or irreversible damage to the membranes. The presence of suspended solids and contaminants such as iron and calcium, cause scaling and deposits which impair functionality and require periodic cleaning with harsh chemicals, resulting in interrupted processing and a reduced membrane lifecycle.
Therefore, utilization of membrane filtration treatment processes such as reverse osmosis membranes for streams of fluid containing hydrocarbons, requires preliminary treatment to remove hydrocarbons, solids and scaling and deposit contaminants from the stream of fluid before it encounters the membrane. A prevalent preliminary treatment approach is ceramic membrane ultra-filtration. However, ceramic membranes require frequent backwash cleaning cycles to remove trapped hydrocarbons, solids and contaminants. Cleaning periodically interrupts processing. It also generates a backwash fluid waste stream which requires disposal. Costs include backwash fluid waste disposal services, a supply of hazardous cleaning chemicals and a dependency upon expensive consumable replacement membranes.
A need therefore exists, for a cost-effective preliminary treatment which enables effective utilisation of auxiliary treatment methods such as reverse osmosis membranes.
Surface wastewater generated in hydrocarbon extraction industry activities may become contaminated with drilling mud, hydrocarbons and chemicals. Current industry management practices include transportation and disposal into an injection well or use of a boiler to evaporate contaminated surface wastewater. Boiler evaporation is environmentally undesirable because the contaminants in untreated water are also discharged into the atmosphere. Additionally significant quantities of diesel fuel are consumed to heat the boiler, particularly during winter drilling activities when the volume of diesel fuel consumed may be equivalent to the volume of water to be evaporated.
There is therefore an increasing industrial need for effective, economically viable and environmentally sustainable processes for enabling the treatment, and re-use or discharge, of wastewater containing hydrocarbons, suspended solids, and contaminants which include but are not limited to dissolved solids, naturally occurring compounds and synthetic additives.
SUMMARY OF THE INVENTION
These and other needs are addressed by the present invention which is directed generally to extraction of hydrocarbons from a wastewater source. Valuable hydrocarbons can be recovered and wastewater can be re-used for industrial purposes, or re-used for agricultural purposes, or discharged to the environment.
In a first embodiment of the present invention, there is provided a method for extracting hydrocarbons from wastewater, comprising providing a source of wastewater comprising hydrocarbons, water, suspended solids and contaminants in a mixture; treating said wastewater to separate said hydrocarbons from said wastewater; isolating said suspended solids; releasing, from the mixture, said water and said hydrocarbons in discrete phases; collecting on a movable collection surface, said hydrocarbons; discharging the collected hydrocarbons; filtering said water progressively in a plurality of individual stages; and discharging the filtered water.
The present invention, can be applied as an alternative preliminary treatment which enables effective utilization of reverse osmosis membranes. For example, the present invention can extract suspended solids of a size greater than 1 micron. It can extract or significantly reduce the level of selected other contaminants. In another example, the present invention extracts more than 99.8% of hydrocarbons from a fluid stream. Those hydrocarbons are recovered in valuable, marketable condition satisfying applicable industry specifications for pipeline shipment and storage.
In yet a further embodiment of the present invention, there is provided a system for continuous extraction and recovery of hydrocarbons from a wastewater source comprising hydrocarbons and water, comprising means for inducing separation of hydrocarbons from water in said wastewater; a plurality of vertically aligned weir panels disposed in said wastewater to coalesce and migrate said hydrocarbons to a layer above said water in said wastewater; a movable collection surface for skimming hydrocarbons from said water, a first collector for collecting said hydrocarbons from said surface; a filtration array for filtering said water; and a second collector for collecting said filtered water.
In a particularly preferred embodiment, the system further comprises an exhaust module for discharge by atomization and evaporation of said filtered water to the atmosphere.
For example, the present invention may be a system that can be rendered in a robust, portable configuration designed for reliable operation at remote locations. The throughput capacity of the system can be increased by using more powerful pumps without a proportionate increase in size. This allows the system of the present invention to retain a portable format at significantly increased capacity.
Operating costs may be reduced as a result of automation and remote monitoring of the present invention, which requires less skilled operations personnel at remote sites, no backwash fluid waste disposal services, no supply of hazardous cleaning chemicals, and incorporates reusable stainless steel filter elements with ultrasonic agitation cleaning, which minimizes dependencies on consumable items to a disposable scavenger filter.
In another embodiment, the present invention can be applied as an alternative surface wastewater treatment system. Valuable hydrocarbons associated with hydrocarbon based drilling mud can be recovered and reused on site. Treated water can be reused on site in industrial processes reducing the need to source and transport fresh water to remote locations.
In still a further aspect of the present invention, treated water may be discharged to the environment in an environmentally sustainable manner. For example, the treated water may be discharged to the ground, a water body such as a river, lake or ocean, or discharged by atomization and evaporation directly to the atmosphere. Discharging the treated water to the environment via any of these methods, reduces the large fuel consumption that is typically utilized by a conventional crude evaporation boiler. This reduces both direct costs for fuel and indirect costs for transportation of that fuel to remote locations or offshore drilling platforms. In addition, instead of evaporating associated contaminants together with the water, the present invention treats the water to applicable environmental standards before discharging it to the atmosphere.
One object of one embodiment of the present invention is to provide an improved process for hydrocarbon extraction.
The improvements in the method and apparatus are realized in one aspect in the selection of a self priming positive displacement suction pump which enables self contained capability to intake fluids from a passive reservoir of wastewater. Determination of the intake pump flow rating capacity and flow control maximizes the processing capacity of the entire system which depends on sufficient wastewater intake flow.
Further, the technology discussed herein takes advantage of the surface area and power rating of a mineral coated submerged electric thermal heating element to deliver sufficient thermal energy to the intake stream of wastewater to break the bonding between emulsions of water and hydrocarbons and detach those hydrocarbons in preparation for separation, coalescence and migration to the surface.
The shape and placement of a heating element used in the system maximizes the thermal surface area exposed to the intake stream of wastewater.
The structure of a containment shroud around the heating element maximizes the duration of exposure of the intake stream of wastewater to contact, or be in close proximity with, the heating element. As a further advantage to the system, determination of the volume, air pressure and size of bubbles injected into the wastewater maximizes the separation of hydrocarbons.
The structure and arrangement of the array of weir panels maximizes hydrocarbon separation, coalescence and migration to the surface. To complement this, the structure of the water diversion weir panel effectively circulates water to the bottom of a skimming tank and maintains the segregation of that water for transfer to the filtration stage.
The sequential procedure of draining clear fluids consists of draining fluid through the sidewall outlet, detecting the fluid level indicating completion of that preliminary step, opening the bottom outlet drains, then purging turbid fluids and settled solids separately through those drains. This procedure enhances complete filtration of the large volume of clear fluids by separating and delaying filtration of a smaller volume of turbid fluid containing a high concentration of settled solids which avoids premature plugging of filter elements and reduction of processing throughput.
The selection of a highly ionic charged material with specific oleophilic properties for the surface of the rotating drum maximizes hydrocarbon extraction.
The arrangement of the size, placement, and depth of immersion of the movable collection surface, in this case, an oleophilic drum and the orientation of an associated skimming wiper, maximizes hydrocarbon extraction and recovery.
The control of the rotational direction, intermittent or continuous operation and variable speed of the oleophilic drum maximizes hydrocarbon extraction and recovery under various conditions.
The arrangement of the hydrocarbon wiper funnel and conduit pass vertically through the interior of the skimming tank. This conserves space, minimizes plumbing fixtures, promotes the gravity flow of hydrocarbons and delivers hydrocarbons directly to the lowest point of the sloped bottom of the recovery tank.
Hydrocarbons recovered are segregated into a tank of specified volume with a level sensor that triggers the periodic discharge of all hydrocarbons in that tank, accompanied by electronic tracking of the number of discharge cycles.
The structure of the recovery tank has a sloped bottom to promote complete and rapid drainage of the full volume of hydrocarbons.
This integrated volumetric discharge technique offers a primary means of measurement, or a supplemental means of validating, the amounts of hydrocarbons recovered. It provides an alternative to depending on remote external metering of a continuous discharge stream of hydrocarbons, the results of which may be subject to meter calibration, tampering and reliability concerns.
A metering sensor is used to monitor and adjust water flow throughout the system to maximize processing capacity and avoid imbalances in flow rates, pressures and holding tank reservoir capacities. Conveniently, a self priming positive displacement pump with a specified rating is used to ensure constant throughput and maintain adequate water flow to maximize processing capacity.
The arrangement of filter material, referred to in this document as pods, in a sequential array enables progressive filtering of solids by passing the stream of water through progressively finer particle filter elements and the filtering of contaminants by passing the stream of water through a scavenger filter element.
The selection of a material with specific adsorptive properties for the scavenger filter element maximizes the filtration of fine solids and contaminants.
The arrangement of an array of standard size filter pods enables flexibility in selecting the desired sequence of filtration based on the volume and size of solids and contaminants present in the wastewater. For example, the filter elements inserted in a sequence of, for example, three filter pods could be a 40 micron particle filter, a 1 micron particle filter and a scavenger filter, or all filter pods could have scavenger filter elements inserted.
The arrangement of each array of filter pods in staggered tiers enables direct structural connections between the offset inlet flange and outlet flange of each filter pod in sequence. This eliminates reliability issues associated with flexible hoses and connectors, promotes effective drainage and conserves space.
Multiple banks of filter arrays with associated flow pressure sensors enables detection of plugged filter elements, and automatic switching of the water flow to an alternate filtration array. This enables uninterrupted operation during the periodic cleaning and replacement of filter elements. This differs from alternate processes that use a backflush procedure to purge trapped solids, which interrupts filtration operations, reduces processing capacity, requires additional pumps and equipment and generates additional volumes of waste fluids for disposal.
Each filter pod includes a pressure relief valve. This enables complete and rapid purging of the filtration array during operations, filter element replacement, maintenance and shutdown by avoiding the creation of an internal vacuum within the filter pods.
The use of reusable stainless steel filter elements minimizes operational dependency on the availability of consumable supplies and reduces the environmental impact of disposable filter elements. Integration of an ultrasonic agitation cleaning system enables the use of reusable filter elements, enables continuous filtration operations and the capture and disposal of solids trapped during filtration. This differs from alternative processes such as high pressure water cleaning which results in abrasion reducing the useful life of reusable filter elements, and generates additional volumes of waste fluids for disposal.
The use of a matrix of control valves allows the option of directing water in real time, for either re-use or environmentally sustainable discharge, or dividing the stream of water proportionately between those options.
An organic scaling prevention treatment reduces the formation of mineral deposits which would otherwise impair heat transfer and diminish the lifecycle of the heater components.
The water tank includes level sensors and controls which turn off the heating element if the volume of water falls below a specified threshold. Upon shutdown the controlled circulation of water produces a gradual cool down of the heater and associated elements. This prolongs the lifecycle of the heater and reduces thermal stress and cracking of associated elements of the system.
The selection of a type of transfer pump which maintains a constant flow despite fluctuations in backpressure is necessary to manage the flow control required to achieve the characteristics needed for effective atomization of water upon discharge at the exhaust orifice.
The heater has been modified by adding dual temperature sensors which detect the surface temperature of the heating element and the temperature of the water separately. This provides more precise control of temperature parameters and protects the heating element from being overloaded.
The process of combined temperature, pressure and flow control is required to achieve the characteristics needed to accomplish atomization of the water upon discharge to ambient temperature and pressure.
The structure of the exhaust tube includes an internal central outlet combined with a surrounding return channel connected to an inverted cone at the exhaust orifice. This enables two way flow of water to be discharged for atomization and condensation captured for circulation back to the holding tank. During cold weather operation the return surrounding the exhaust outlet provides a measure of insulation.
The nature of the exhaust orifice produces a rapid drop in water temperature and pressure which results in an enhanced atomization discharge effect. This substantially reduces heating requirements and increases fuel efficiency compared with alternative thermal evaporation boiler techniques. The selection of the size and shape of the exhaust orifice and automated control of flow and heater temperature enables control of pressure and temperature to optimize vaporization upon release to the atmosphere at varying differences in temperature and pressure between the internal vessel and the outside atmosphere. A pump that maintains prescribed volume and pressure, despite fluctuations in temperature, transfers water to an inline heater. As the heater increases temperature, the pressure increases, requiring detection by pressure, temperature and flow sensors and automated controls to adjust and maintain the desired pressure, temperature and throughput volume to optimize effective atomized discharge. The inverted cone on the end of the exhaust tube captures released water droplets that have not fully vaporized and returns them to the input to the heater through the hollow channel around the outside of the exhaust tube.
The direction of water for re-use provides an alternative to discharge or disposal of wastewater. This reduces requirements for fresh water intake by industrial processes.
Constant or periodic application of auxiliary processes including reverse osmosis membranes, an enhanced orifice discharge technique, and other known treatment techniques, is proposed as a means for segregating and eliminating contaminants from the water, including without limitation dissolved solids and salts. This further extends the life cycle of process water, reduces waste discharge streams and further reduces requirements for fresh water intake by industrial processes.
The arrangement of automation elements required for coordinated monitoring and control of the processes and procedures reduces opportunities for human error and minimizes requirements for skilled human operation resources on-site. As a consequence it enhances operational reliability, avoids repairs and maintenance, maximizes processing capacity, and maximizes operating cost efficiencies at remote locations.
Computer software program instructions implement the logic governing the monitoring and control of the processes and procedures involved in the method.
The system also integrates a telecommunications system which enables remote data transfer and digital communication for implementing the method, operational management, diagnostic fault analysis, maintenance and repair.
The features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages of the present invention may become apparent upon reviewing the following detailed description and drawings of non-limiting examples and embodiments in which:
FIG. 1 is a flow diagram of the process steps involved in the methodology;
FIG. 2 is a partially cut away perspective view of one embodiment of the apparatus of the present invention;
FIG. 3 is a top plan view of FIG. 2 ;
FIGS. 4 and 4A are isolated perspective views of the skimmer unit for use with the present invention; and
FIG. 5 is a schematic illustration of an alternate embodiment.
FIG. 6 is a diagram of the process steps involved in atomized discharge of water to the atmosphere through an exhaust tube and orifice.
Similar numerals employed for the drawings denote similar elements
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 shows a schematic of the overall process denoted by numeral 10 .
During the separation and recovery stage of processing, water combined with hydrocarbons, suspended solids, and contaminants, referred to in this document as wastewater is processed to separate, extract and recover hydrocarbons in measured quantities, purge any settled suspended solids and segregate the remaining fluid for filtration processing. Contaminants include but are not limited to, naturally occurring compounds, synthetic additives and dissolved solids and comprise suspended mineral salts, dissolved chlorides, naturally occurring radioactive materials, (“NORMs”), ions, chemicals and other substances.
Referring to FIG. 1 , an external source of wastewater, 12 , is in fluid communication with a self priming positive displacement suction pump 14 to produce an intake stream of wastewater. Intake flow is controlled by flow control device 16 based on processing and capacity parameters.
As the wastewater is transferred into a skimming tank, generally denoted by numeral 18 , the intake stream of wastewater passes in close proximity to a heating element 20 to breakdown emulsions of water and hydrocarbons which are present.
As an alternative, the emulsions may be broken by agitation, chemical additives or a combination of these and heat.
A dispersed air or induced gas, flotation generator associated with the skimming tank 18 , generally denoted by numeral 22 , injects air or non-reactive gas bubbles into the wastewater to enhance the rapid and complete phase separation and migration of hydrocarbons into a layer flowing on the surface of the skimming tank 18 to have discrete phases. Examples of suitable non-reactive gases include for example, carbon dioxide and ozone.
In the skimming tank 18 , the wastewater flows through coalescing elements shown as multiple vertically aligned weir panels 24 in FIG. 4A , of progressively increasing length, submerged below the surface and extending to progressively increasing depth. The weir panels 24 divert the flow of wastewater to increasing depths, exposing the hydrocarbons to increased hydrostatic pressure. The hydrocarbons separate from the remaining wastewater, collect on the weir panels 24 , amalgamate through coalescence and migrate to the surface of the skimming tank 18 .
Separated hydrocarbons form a layer floating on the surface of the skimming tank 18 . A portion of the solids suspended in the wastewater settle to the bottom of the skimming tank 18 . The remaining water is diverted toward the bottom of the skimming tank 18 . An additional diversion weir panel (not shown) prevents water from rising to the surface and channels the flow of water from the bottom of the tank 18 to a primary outlet O located on the sidewall of the skimming tank 18 . The diversion weir 28 circulates water to the bottom of the skimming tank 18 for transfer to a collector tank 32 for the filtration stage 44 .
Settled solids and fluids are periodically discharged from the skimming tank 18 during purging cycles as denoted by numeral 30 . During purging, fluid is initially discharged from the sidewall outlet O. A sensor (not shown) detects when the level of fluid in the skimming tank 18 falls below the level of that sidewall outlet O. Upon activation of that sensor, outlet drains (not shown) located at the bottom of the tank are opened, purging the settled solids and remaining fluids for filtration.
A movable collection surface, generally denoted by numeral 34 , and shown in the example as a rotating drum with a surface is positioned at the top of the skimming tank 18 and is adapted to be partially immersed in the fluid. As is well known, hydrocarbons adhere to materials which have oleophilic properties. In one embodiment, the surface is composed of an oleophilic material. The drum 34 rotates in a direction which causes the surface flotation layer of hydrocarbons to adhere to the rotating drum 34 and be extracted upward from the surface of the fluid. An associated wiper blade (not shown) skims the rotating drum 34 and deflects the extracted hydrocarbons into a funnel (not shown) with an outlet channel (not shown) connected to a recovery tank 36 . Other mechanical means may be used to deflect and collect the hydrocarbons.
In an alternative embodiment, the surface of the movable collection surface 34 may comprise mechanical skimming elements such as rubber or metal discs or brushes that skim the hydrocarbons, especially in cases where the hydrocarbon layer is particularly viscous.
Recovered hydrocarbons are temporarily segregated into the recovery tank 36 with a specified volume capacity. A sensor (not shown) monitors the level of hydrocarbons and determines when the recovery tank 36 is full. Upon activation of that sensor the recovery tank 36 is completely emptied by a discharge pump 38 , which results in the discharge of that specified volume of recovered hydrocarbons into an external storage vessel (not shown). The number of discharge cycles is automatically recorded.
A flow meter 40 and pump 42 , an example of which is a self priming positive displacement suction pump are applied to measure and transfer a stream of water through the skimming tank 18 sidewall outlet to the filtration stage, globally denoted by numeral 44 .
Filtration is undertaken by passing water through an array of multiple, directly connected filter pod housings 46 through 56 . Each filter pod housing in the array is configured to contain multiple filter elements (not shown). The filter elements inserted in any particular pod housing array may all be a similar or different type and filtration size rating, For example particle filter elements may be used and are reusable stainless steel absolute filters ranging in size between 40 microns and 1 micron. Fine particle, hydrocarbon and contaminant scavenger filter elements may also be used and are a specialized composition of disposable adsorptive material. As a further example, ultrafiltration filter elements may also be used in a filter element and include ceramic membranes with an integrated backwash flush cleaning system.
Depending on the nature of solids and contamination contained in the wastewater, different combinations of filtering sequences may be used. The filtration sequence captures solids of progressively reduced size together with contaminants. For example, a typical filtration sequence may be composed of a primary pod containing 40 micron particle filter elements, a secondary pod containing 1 micron particle filter elements, and a final pod containing scavenger filter elements.
Filtration arrays are arranged in multiple redundant banks either serially or in parallel to provide for continuous flow and filtration operation during the cleaning, maintenance and replacement procedures for any particular array of filter pods. Pressure differential sensors (not shown) in the filter pod housing detect plugged filter elements, shutoff the flow to that filtration array and divert the flow to another filtration array to enable the performance of filter element cleaning, maintenance and replacement.
An ultrasonic agitation filter element cleaning system 41 may be associated with the filtration stage 44 to enable the performance of periodic cleaning and reuse of reusable filter elements in the pods 46 through 56 and the capture and disposal of filtered solids at 43 . Scavenger filter elements are disposable after use.
Following filtration, an array of control valves 58 direct the water for re-use 60 , or for environmental discharge, for example atmospheric discharge 62 , or divides it proportionately between re-use and atmospheric discharge. Re-use of filtered water could be for a range of industrial purposes, such as in hydrocarbon extraction operations or as gray water.
Accordingly, in one embodiment, the present invention may comprise an exhaust module for discharge by atomizing the filtered water and evaporating it to the atmosphere and shown in detail in FIG. 6 . An organic coating substance is introduced into water directed for atmospheric discharge, to prevent the formation of scale and mineral deposits, shown as operation 64 on the surface of heating elements. Upon contact with the heating elements, the substance forms a coating which has an acidity level that inhibits the formation of scale and also acts as a barrier blocking direct adhesion of scale.
Following the scaling prevention treatment 64 the stream of water is transferred into water and condensation recovery tank 66 for discharge to the atmosphere. As seen in both FIG. 1 and FIG. 6 , from tank 66 the water is transferred to a heater 68 by a transfer pump 70 , an example of which is a positive displacement hydraulic cell pump, capable of maintaining a constant volume flow independent of fluctuations in back pressure.
The stream of water is introduced into a heater 68 with an associated mineral coated electrical element. The water is heated to controlled temperature and pressure. Periodically the contents of the heater 68 are purged under pressure to remove scale deposits. This operation is denoted by numeral 72 .
The pump 70 maintains prescribed volume and pressure, despite fluctuations in temperature, as it transfers water to the heater 68 . The heater outlet is monitored by temperature, pressure and flow sensors, and controls, globally denoted by numeral 69 in FIG. 1 and 69 a , 69 b , and 69 c respectively in FIG. 6 , which maintain specified discharge, temperature and pressure characteristics, and throughput volume to optimize effective discharge of atomized water 76 .
The heater outlet is connected to the external atmosphere through a vertical exhaust tube and an exhaust orifice, referenced by numerals 71 and 74 in FIG. 1 . The length of the removable exhaust tube is variable, depending on the height and orientation of the exhaust plume needed to accomplish the desired atmospheric dispersion.
Referring to FIG. 6 , the exhaust tube 71 is comprised of an inner exhaust outlet 71 a separated from a surrounding condensation return channel 71 b . An inverted condensation collection cone 78 attached to the exterior end of exhaust outlet 71 a at the exhaust orifice 74 collects condensation and water and circulates it back through the condensation return channel 71 b to the water and condensation recovery tank 66 .
The size, shape and nature of the exhaust orifice 74 produces a combination of atomization, vaporization and evaporation effects as a result of the controlled heating, pressurization and flow of water followed by a rapid change to ambient temperature and pressure though the exhaust orifice.
Following filtration, as an alternative to discharging the water, the stream of water may be re-used in industrial processes.
Eventually, continuously re-used process water will become saturated with escalating levels of suspended solids or contaminants including dissolved solids contributed by upstream industrial processes. Based on a determination of the nature of the suspended solids and contaminants and saturation levels concerned, auxiliary processing techniques may be combined to supplement the method.
These auxiliary processes may include enhanced orifice discharge segregation techniques or other known techniques including without limitation, ceramic plate techniques and reverse osmosis membrane techniques, either in combination, or independently. Through constant or periodic, application of auxiliary contaminant reduction treatment, water which inherently contains, or eventually accumulates, unacceptable contaminant saturation levels can be conditioned to a reusable state. The auxiliary processes selected will depend on the specific content of the process water. Other unit operations useful for auxiliary processing include the use of activated alumina, activated carbon, aeration, anion exchange, precipitation, chlorination, distillation, mechanical filtration, oxidizing filters, reverse osmosis membranes, ultraviolet exposure, inter alia.
The operating parameters of the processes and procedures comprising the method, including without limitation, temperature, pressure, flow rates, volume, status and other characteristics are monitored and controlled by a configuration of elements including a programmable logic controller, touch screen display, sensors, drives, keypads, indicators, switches, data storage devices, telecommunications devices and technology systems.
It will be appreciated by those skilled that the entire process can be logically controlled for precise execution of all unit operations.
Of particular benefit is the fact that the method offers scalable processing capacity. Systems implementing the method may be fabricated in a portable configuration or as a fixed plant installation with a larger processing capacity. The elements of such systems are scalable to accommodate increased capacity. For equipment components which are only available in a limited size, arrays of multiple components can accommodate increased capacity.
Referring now to FIG. 2 , shown is an example of portable apparatus of the configuration. The apparatus is generally denoted by numeral 80 . The container 82 housing the components is an explosion proof material with an internal observation window 84 from the heated filtration and discharge process enclosure which is heated with heater 86 and accessible by human operators. Additionally, the arrangement of the elements of the complete system are organized to fit within a standard size transport container and to maximize processing capacity within that limited space. FIG. 3 illustrates the arrangement in plan view. The remaining internal components have been discussed in connection with FIG. 1 .
FIG. 4 illustrates a first embodiment of the skimmer tank 18 referred to in this document. As is illustrated, the skimmer tank 18 provides the movable collection surface 34 for collecting the hydrocarbons as established earlier. The surface is illustrated as drum, however, the surface could easily be any suitable configuration, such as a track or a polygonal arrangement as is illustrated in FIG. 5 . Other suitable high surface area arrangements will be readily apparent to those skilled in the art.
Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as outlined in the claims appended hereto. The entire disclosures of all references recited above are incorporated herein by reference. | Method and system for extracting and recovering hydrocarbons from wastewater and treating the water to improve its condition. A series of specific unit operations result in the extraction of hydrocarbons, solids and contaminants and the treatment of water to a condition which is fit for re-use or environmentally sustainable discharge. Phase separation between the water and hydrocarbons is effected using flotation techniques followed by collection of the hydrocarbons using a movable collection surface. The aqueous phase is processed by multiple filtration steps. The result is significant extraction and recovery of hydrocarbons and conservation of water for re-use or discharge to the environment in a process which is continuous and scalable for large or small operations. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a quick release assembly for a commode or toilet seat. More specifically, the present invention relates to a quick release hinge assembly employing a cam and compression system that is easily used with existing seat hinge and commode designs providing simple employment and an attractive appearance.
[0003] 2. Description of the Related Art
[0004] A wide verity of hinge mechanisms, toilet seats, and combinations thereof have been created to deal with consumer demands for security and stability, easy removal (quick release), easy replacement upon breakage and a clean visual appearance. These mechanisms provide solutions spanning nearly the entire twentieth century and follow the evolution of the toilet mechanism itself. A brief selection of these references follows.
[0005] A substantial number of these mechanisms provide solutions for easy replacement or removal and corresponding stability concerns, and include: U.S. Pat. No. 4,319,365 to Bemis, U.S. Pat. No. 2,593,534 to Campanelli, U.S. Pat. No. 3,063,063 to Brooks; U.S. Des. No. D377,306 to Decker, U.S. Pat. No. 3,055,015 to Silverman, U.S. Pat. No. 3,653,077 to Warnberg, U.S. Pat. No. 3,082,000 to Waldon, U.S. Pat. No. 3,613,130 to Sansone, U.S. Pat. No. 3,471,874 to Dixon, U.S. Pat. No. 4,367,567 to Sandoykas, U.S. Pat. No. 5,267,357 to Ades, U.S. Pat. No. 5,396,663 to Burgess, U.S. Pat. No. 5,414,875 to Kappl et al., U.S. Pat. No. 5,638,554 to Corzine, U.S. Pat. No. 6,070,295 to Helsebus, U.S. Pat. No. 6,071,034 to Cavagna, U.S. Pat. No. 6,101,640 to Brewer et al., U.S. Pat. No. 6,338,167 to Baker et al., U.S. Pat. No. 6,381,762 to Moser, U.S. Pat. No. 6,643,851 to Janes, U.S. Pub. No. 2001/0013143 A1 to Cavagna, U.S. Pub. No. 2004/0064876 A1 to Lu, U.K. App. No. 2 067 650 A to Baillie et al, DE Pat. No. DE4339200 to Burkard, and DE Pat. No. DE19958371 to Joerg et al.
[0006] Additional references focus on the hinge itself, or the hinge joint between the seat and lid. These references include: U.S. Pat. No. 4,133,061 to Hurd, U.S. Pat. No. 4,173,802 to Wikstrom, U.S. Pat. No. 4,159,548 to Hewson, U.S. Pat. No. 4,353,137 to Jammet, U.S. Pat. No. 4,688,274 to Ginsburg et al., U.S. Pat. No. 4,680,816 to Colombani, U.S. Pat. No. 4,688,274 to Grimstad, U.S. Pat. No. 4,965,889 to Tissot et al., U.S. Pat. No. 4,974,262 to Rosen, U.S. Pat. No. 5,175,891 to Ohshima et al., U.S. Pat. No. 5,515,552 to Tolsma, U.S. Pat. No. 5,901,383 to Yanagawa et al., U.S. Pat. No. 5,933,875 to Hulsebus et al., U.S. Pat. No. 5,980,150 to Newman et al., U.S. Pat. No. 6,421,842 to Fujita, U.S. Pat. No. 6,453,478 to Semmler, and U.S. Pat. No. D358,973 to Spaeth.
[0007] While the long list of references above provides a range of solutions to the concerns noted above, none provides the unique benefits and operation of the present design.
OBJECTS AND SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide a quick release or easy engagement hinge mechanism.
[0009] Another object of the present invention is to provide a quick release or engagement mechanism that is operable by a wide number of users and provides a pleasing appearance.
[0010] Another object of the present invention is to provide a quick release hinge assembly that is reasonably cost effective to produce inexpensive to a customer.
[0011] The present invention relates to a quick attachment and release assembly that enables ready attachment of a variety of seat combinations to a variety of ceramic supports with variable depth and diameter attachment holes. A cam assembly with a lever arm enables compression of at least one elastomeric sleeve positioned about a central shaft after insertion within an attachment hole. During compression the one or more elastomeric sleeves expand outwardly gripping walls of the hole and fixing a pivoting flange of the seat relative to the hole.
[0012] Adaptive embodiments enable the use of additional spacers and adjustable-length bottom stops to adapt the present invention to a variety consumer needs and differently manufactured ceramic supports.
[0013] According to an embodiment of the present invention there is provided an assembly, comprising: a seat member having an attachment member with a first opening, a seat support having a seat attachment hole, a quick release/attachment assembly projecting through the first opening and into the attachment hole, the quick release/attachment assembly, further comprising: a lever arm having a first cam member with a first cam surface, a central shaft extending from a pivot point of the lever arm at a proximate end to a bottom stop at a distal end, a stability member about the central shaft proximate the proximate end having a second cam surface proximate the first cam surface, and an elastomeric sleeve about the central shaft between the bottom stop and the stability member, whereby when the lever arm actuates the first cam surface along the second cam surface, the bottom stop is drawn toward the pivot point compressing the elastomeric sleeve and bulging the sleeve to grip walls of the seat attachment hole and join the seat attachment member to the seat support.
[0014] According to another embodiment of the present invention, there is provided an assembly further comprising: a cover cap member, and means for positioning the cover cap member covering a portion of the lever arm and the quick release/attachment assembly, whereby the cover cap member provides a pleasing visual appearance after installation.
[0015] According to another embodiment of the present invention, there is provided an assembly further comprising: an opening on the cover cap member, and a portion of the lever arm projecting through the opening enabling the cover cap member to provide the pleasing visual appearance while retaining a compact shape.
[0016] According to another embodiment of the present invention, there is provided a quick release/attachment assembly, comprising: a lever arm having a first cam member with a first cam surface, central shaft extending from a pivot point of the lever arm at a proximate end to a bottom stop at a distal end, stability member about the central shaft proximate the proximate end having a second cam surface proximate the first cam surface, an elastomeric sleeve about the central shaft between the bottom stop and the stability member, whereby when the lever arm actuates the first cam surface along the second cam surface, the bottom stop is drawn toward the pivot point compressing the elastomeric sleeve and bulging the sleeve to grip walls of an external seat attachment hole and join an external seat attachment member to an external seat support, a cover cap member, and means for positioning the cover cap member covering a portion of the lever arm and the quick release/attachment assembly, whereby the cover cap member provides a pleasing visual appearance after installation.
[0017] According to another embodiment of the present invention, there is provided a quick release/attachment assembly, further comprising: an opening on the cover cap member, and a portion of the lever arm projecting through the opening enabling the cover cap member to provide the pleasing visual appearance while retaining a compact shape.
[0018] According to another embodiment of the present invention, there is provided an assembly, comprising: a seat member having an attachment member with a first opening for joining with an external seat support having an attachment hole, a quick release/attachment assembly projecting through the first opening and into the attachment hole, the quick release/attachment assembly further comprising: a lever arm having a first cam member with a first cam surface, a central shaft extending from a pivot point of the lever arm at a proximate end to a bottom stop at a distal end, a stability member about the central shaft at the proximate end having a second cam surface proximate the first cam surface, and an elastomeric sleeve on the central shaft between the bottom stop and the stability member, whereby when the lever arm actuates the first cam surface along the second cam surface, the bottom stop is drawn toward the pivot point compressing the elastomeric sleeve and bulging the sleeve away from the central shaft to grip walls of the seat attachment hole and join the seat attachment member to the seat support.
[0019] According to another embodiment of the present invention, there is provided a method for affixing a toilet seat to a support, comprising the steps of: providing a seat member having an attachment member with at least a first opening, positioning the seat member on a seat support having at least one seat attachment hole, aligning the first opening with the seat attachment hole, inserting a quick release/attachment assembly through the first opening and into the attachment hole, the quick release/attachment assembly further comprising: a lever arm having a first cam member with a first cam surface, a central shaft extending from a pivot point of the lever arm at a proximate end to a bottom stop at a distal end, stability member about the central shaft at the proximate end having a second cam surface proximate the first cam surface, and an elastomeric sleeve about the central shaft between the bottom stop and the stability member, whereby when the lever arm actuates the first cam surface along the second cam surface, the bottom stop is drawn toward the pivot point compressing the elastomeric sleeve and bulging the sleeve to grip walls of the seat attachment hole and join the seat attachment member to the seat support.
[0020] According to another embodiment of the present invention, there is provided an attachment and adjustment kit, comprising: a first member having an attachment member with a first opening for joining with an external first support having an attachment hole, a quick release/attachment assembly projectable through the first opening and into the attachment hole during an assembly, the quick release/attachment assembly further comprising: a lever arm having a first cam member with a first cam surface, a central shaft extending from a pivot point of the lever arm at a proximate end to a bottom stop at a distal end, means for adjusting a position of the bottom stop on the central shaft relative to the pivot point thereby allowing the quick release/attachment assembly to adapt to differing length attachment holes in the seat support, stability member about the central shaft at the proximate end having a second cam surface proximate the first cam surface, at least one elastomeric sleeve on the central shaft between the bottom stop and the stability member, and thereby when the lever arm actuates the first cam surface along the second cam surface, the bottom stop is drawn toward the pivot point compressing the elastomeric sleeve and bulging the sleeve away from the central shaft to grip walls of the seat attachment hole and join the seat attachment member to the seat support.
[0021] According to another embodiment of the present invention, there is provided an attachment and adjustment kit, further comprising: at least one spacer on the central shaft, and the at least one spacer being one of proximate the bottom stop and proximate the stability member.
[0022] According to another embodiment of the present invention, there is provided an attachment and adjustment kit, wherein: the means for adjusting includes a threaded connectability between the central shaft and the bottom stop, thereby allowing the bottom stop to be threadably adjusted along a length of the central shaft.
[0023] According to another embodiment of the present invention, there is provided an attachment and adjustment kit, wherein: the elastomeric sleeve is at least one of a cylendraceous member, a hexagonal member, an octagonal member enabling simple operation and formation, and an external surface of the elastomeric sleeve is at least one of a smooth surface, a roughened surface, a patterned surface, a particulate surface enabling firm fixing to a surface during use.
[0024] According to another embodiment of the present invention, there is provided a kit, comprising: a quick release/attachment assembly comprising a lever arm having a first cam member with a first cam surface, a central shaft extending from a pivot point of the lever arm at a proximate end to a bottom stop at a distal end, means for removing and adjusting a position of the bottom stop on the central shaft relative to the pivot point thereby allowing the quick release/attachment assembly to adapt to differing length operations, a stability member about the central shaft at the proximate end having a second cam surface proximate the first cam surface, at least one elastomeric sleeve on the central shaft between the bottom stop and the stability member, and thereby when the lever arm actuates the first cam surface along the second cam surface, the bottom stop is drawn toward the pivot point compressing the elastomeric sleeve and bulging the sleeve away from the central shaft to grip walls of the seat attachment hole and join the seat attachment member to the seat support.
[0025] According to another embodiment of the present invention, there is provided a kit further comprising: a cover cap member, and means for positioning the cover cap member covering a portion of the lever arm and the attachment assembly, whereby the cover cap member provides a pleasing visual appearance after installation.
[0026] According to another embodiment of the present invention, there is provided a kit further comprising: an opening on the cover cap member, and a portion of the lever arm projecting through the opening enabling the cover cap member to provide the pleasing visual appearance while retaining a compact shape.
[0027] The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conduction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a partially cut-away perspective view of one embodiment of the present invention.
[0029] FIG. 2 is a top view of the embodiment shown in FIG. 1 .
[0030] FIG. 3 is a partial sectional view of FIG. 1 along line 3 - 3 .
[0031] FIG. 4 is a partially cut-away perspective view of another embodiment of the present invention.
[0032] FIG. 5 is a partial sectional view of FIG. 4 along line 5 - 5 splitting the central shaft and the quick release attach assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring now to FIGS. 1-3 , a seat hinge assembly 1 includes at least a pivoting seat flange 4 and a quick attach/release assembly 6 . A seat top 2 and a seat bottom 3 are pivotally joined to pivoting seat flange 4 in a conventional manner.
[0034] Hinge assembly 1 rests on a ceramic or other support 5 relative to a plurality of holes 14 conventionally supplied by a manufacturer for seat attachment and securement. As shown, flange 4 extends from a pivoting attachment of seat top 2 and seat bottom 3 and is positionable relative a relative hole 14 , as shown. A cover cap 12 with a cap opening 13 is pivotally joined to flange 4 and facilitates an attractive covering or partial covering of quick attach/release assembly 6 as will be described.
[0035] Quick attach/release assembly 6 includes a central shaft 15 joining a bottom stop member 16 and an upward pivot point or pivot axis 10 . A lever arm 7 is pivotally attached relative to pivot 10 (a pivot point/axis) and rotates relative thereto. Pivot axis 10 is aligned with a center of central shaft 15 , thereby optionally allowing lever arm 7 to rotate relative to central shaft 15 . A stop washer or stability member 11 pivotally encircles central shaft 15 as shown and optionally includes a second cam surface 9 . Lever arm 7 includes a cam member 8 with a first cam surface 8 a . As shown, during operation, lever arm 7 rotates relative to pivot point 10 and slides cam member 8 along cam surface 8 a relative to second cam surface 9 which effectively shortens a distance between stop washer or stability member 11 and bottom stop 16 .
[0036] While lever arm 7 is shown with a shortened and broadened end, any type of ending would be sufficient to operate quick attach/release assembly 6 . In the preferred embodiment shown, the end of lever arm 7 is shortened and broadened for convenient finger use and force application in a small space. Ridges (shown but not numbered) may be employed to minimize user-finger slipping during application.
[0037] As can be seen most advantageously in FIG. 2 , cover cap 12 is joined to pivoting flange 4 and allows cover cap 12 to pivot up and over lever arm 7 after use. In alternative embodiments cover cap 12 may be joined to stability member 11 for convenience and separate sale.
[0038] A cap opening 13 surrounds a later portion of lever arm 7 to provide a pleasing appearance and allow simple cleaning. In this manner, cover cap 12 prevents debris from surrounding quick attach/release assembly 6 and making cleaning difficult.
[0039] In one alternative embodiment, cover cap 12 is optionally joined with stop washer/stability surface 11 and operates as part of quick attach/release assembly 6 . In this embodiment, a conventional pivoting flange 4 (without a cover cap) may be used, and assembly 6 may be provided separately for consumer convenience, for example with cover cap 12 joined to stability member 11 . In this embodiment, convenience is additionally improved by allowing stop washer/stability surface 11 with cap 12 to pivot relative to central shaft 15 while simultaneously allowing lever arm 7 to similarly rotate. As a consequence, in cramped circumstances a user may position and reposition assembly 6 into a desired position.
[0040] In the embodiment shown at least one elastomeric sleeve 17 surrounds central shaft 15 between bottom stop 16 and stop washer 11 . In the present embodiment, sleeve 17 has a cylindrical shape with a wall thickness, but alternative shapes are envisioned, including semi-circular, pseudo-circular, hexagonal, etc. sufficient to both expand outwardly relative to shaft 15 and to grip the inner surfaces of hole 14 .
[0041] As best understood from FIG. 3 , as lever arm 7 actuates to shorten the distance between bottom stop 16 and stop washer/stability member 11 compressive pressure is axially applied to elastomeric sleeve 17 causing the sleeve to bulge outwardly forming expanded sleeve 17 ′. During outward expansion an outer surface of expanded sleeve 17 ′ contacts inner surface of hole 14 placing sleeve 17 under compression and exerting substantial resistance to axial removal of quick release/attach assembly 6 .
[0042] In the present embodiment elastomeric sleeve 17 has an outer surface of gripping rubber to provide a tight gripping fit upon expansion. It is envisioned, that alternative shapes (see supra.) or alternative surface textures (rough surface, aggregate coated, sliced or cut surfaces, roughened, etc.) may be used to enhance slip resistance between sleeve 17 and the inner surface of hole 14 .
[0043] Referring now to FIGS. 4 and 5 an alternative embodiment of the present invention includes a hinge assembly 100 containing an alternative quick attach/release assembly 60 as shown. In the present embodiment it is noted that hole 14 and ceramic support 5 are thickened representing alternative types of conventional toilet casting techniques.
[0044] In the present embodiment, pivoting flange 4 pivotally joins seat top 2 and seat bottom 4 and the assembly pivotally operates in a similar manner to that described above.
[0045] In this embodiment, at least one rigid sleeve or spacer 18 is provided along an extended central shaft 15 ′. In the present embodiment two rigid spacers 18 are on opposite sides of elastomeric sleeve member 17 and loosely slide along and rotate about extended central shaft 15 ′.
[0046] Rigid spacers 18 serve to position elastomeric sleeve member 17 generally centrally within hole 14 and as lever arm 7 actuates exert compressive forces on elastomeric sleeve 17 in the manner described above.
[0047] This embodiment enables the use of uniformly shaped sleeve members 17 having the same or similar compressive strength/resistance as the embodiment described above despite the extended shaft 15 ′. This adaptation allows operation of quick attach/release assembly 60 by assemblers with smaller or weaker hands and minimizes damages due to over tension to ceramic support 5 . As a consequence, alternative embodiments of the present invention allow easy adaptation to a variety of industry ceramic supports without requiring a user to adapt the installation process.
[0048] In another alternative embodiment, a replacement quick attach/release assembly 6 is provided as a kit wherein bottom stop 16 is fixed or optionally removably and adjustably joined (via threads or other mechanism) to central shaft 15 , 15 ′ and allows removal and adjustment relative there to. Included in the kit are a number of different length and optionally thickness elastomeric sleeves 17 , 17 ′ and different length and optionally thickness spacers 18 . During use, a consumer would first assess the thickness of a particular ceramic support 5 and length of hole 14 . Thereafter the consumer would select at least one elastomeric sleeve 17 and install it along shaft 15 and adjust (for example by thread-ably adjusting) bottom stop 16 as required. For especially deep holes 14 , the consumer would employ sleeve 17 and select and install one or more spacers 18 from the kit with the goal of positioning compressive attachment of one or more expanded sleeve' 17 ′ generally centrally within hole 14 for maximum attachment force and resistance to movement. By employing an easily assembled kit with alternative spacers 18 and sleeves 17 , a consumer may adapt the present invention to a variety of attachment conditions for maximum convenience and stability.
[0049] In another alternative embodiment spacers 18 would not be open cylinders loosely fitting about shafts 15 , but would be formed in a solid body with only a single axial opening for the shaft. In this manner, the ends of elastomeric sleeve 17 , 17 ′ are presented with and contact a solid, firm, and supporting surface during use and compression. As a consequence, the risk of elastomeric sleeve 17 expanding into a space defined between shaft 15 and an inner portion of a spacer 18 and releasing the compressive stress on hole 14 , is substantially minimized by eliminating the space.
[0050] In the embodiments discussed above, stop washer/stability member 11 operates effectively to assist assembly 6 to urge pivoting flange 4 against ceramic support 5 during use and provides an additional measure of stability to seat top 2 and seat bottom 3 . It should be understood therefore, that the present assembly fixes a seat to a support both by the pressure applied by the outward forces from elastomeric sleeve 17 , 17 ′, and also by the joining pressure supplied by stop washer/stability member 11 .
[0051] As further discussion it should be noted in FIG. 5 , that member 4 appears to closely surrounds shaft 15 ′ during compression, this is optionally the case in the embodiment shown where bottom member 18 is threadably joinable to shaft 15 ′ and shaft 15 ′ is inserted via a small hole in member 4 and elastomeric sleeves and bottom member 18 are there after assembled. In this alternative manner, the present invention allows for quick adaptation to a variety of situations and constructions while adopting the basic functional aspects described above.
[0052] It should be apparent to those of skill in the art of designing consumer products that embodiments of the present invention may be readily adapted to both the initial product market (sold in combination with a seat assembly), and a product aftermarket (sold as a kit for use with an existing seat assembly). As a consequence, the present invention allows ready adaptation to a variety of market conditions and consumer requirements for product adaptation.
[0053] It should be additionally apparent to those of skill in the art that the present embodiments may be adapted to position elastomeric member 17 at a position below the ceramic support 5 . In this position, during operation, as elastomeric member 17 is compressed and budges outwardly it presses on the bottom surface of ceramic support 5 exerting compressive forces. In this manner, this embodiment may be combined with previous embodiments and different configurations allowing elastomeric member 17 to be positioned within hole 14 or below hole 14 or both.
[0054] In the claims, means- or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw's helical surface positively engages the wooden part, and a bolt's head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures.
[0055] Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | A quick attachment and release assembly enables ready attachment of a variety of seat combinations to a variety of ceramic supports with variable depth and diameter attachment holes. A cam assembly with a lever arm enables compression of at least one elastomeric sleeve positioned about a central shaft after insertion within an attachment hole. During compression the one or more elastomeric sleeves expand outwardly gripping walls of the hole and fixing a pivoting flange of the seat relative to the hole. Adaptive embodiments enable the use of additional spacers and adjustable-length bottom stops to adapt the present invention to a variety consumer needs and differently manufactured ceramic supports. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 62/387,190, filed Dec. 23, 2015, which is incorporated by reference.
BACKGROUND
[0002] Certain institutions are required to have enough resources to cover any incurred or future costs. Sometimes, the existence of these allocated resources or funds is mandated by governing bodies, for example, country and state governments. In some examples, financial institutions are required to have a certain amount of reserve money as a percentage of deposits in order to be able to cover daily withdrawals or emergency withdrawals from their customers. In another example, insurance companies are required to hold enough reserve money to cover any incurred claims.
[0003] The process of determining an amount of reserve money currently employed by insurance companies is conservative due to volatility in current reserving models. Sometimes information needed to accurately predict the required reserve amount is not received until months later. Current methodologies deal with this information lag by providing an incredible margin of safety that burdens institutions with requirements to hold a large amount of capital on hand in the form of reserves money. Large amount of capital on hand may adversely impact an institution's ability to invest in the future.
BRIEF SUMMARY
[0004] Embodiments of the disclosure provide a system and method of allocating a resource based on myriad input data. In some embodiments, the myriad input data include membership information, claims data, transactional data, etc. The myriad input data are sorted and organized in a meaningful association relationship before being applied to a resource allocation modeling algorithm. The resource allocation modeling algorithm provides estimated resources necessary for the application chosen. For example, an insurance company may use membership information, claims data, transactional data, etc., to estimate how much reserve money or funds it should hold to cover future claims within a certain timeframe.
[0005] In one embodiment, a method for estimating reserves for an insurance carrier using a data platform configured to collect data from one or more source systems is provided. The method includes: collecting reserves relevant data from one or more data source systems over a system defined time period; converting the reserves relevant data into a reserves relevant data matrix, wherein the reserves relevant data matrix comprises a plurality of features based on the reserves relevant data that are organized based on the system defined time period; storing the reserves relevant data matrix at a reserves database of the data platform; executing a predictive model for each of the plurality of features of the reserves relevant data matrix to extrapolate a trend for each individual feature; and combining the trend for each individual feature to obtain a reserves estimate.
[0006] In another embodiment, a method for geographically allocating reserves for an insurance carrier using a data platform configured to collect data from one or more source systems is provided. The method includes: collecting reserves relevant data from one or more data source systems from a plurality of geographic regions over a system defined time period; converting the reserves relevant data into a reserves relevant data matrix, wherein the reserves relevant data matrix comprises a plurality of features based on the reserves relevant data that are organized based on the plurality of geographic regions and the system defined time period; storing the reserves relevant data matrix at a reserves database of the data platform; executing a predictive model for each of the plurality of features of the reserves relevant data matrix to extrapolate a trend for each individual feature within a geographic region of the plurality of geographic regions; and combining the trend for each individual feature within the geographic region to obtain a reserves estimate for the geographic region.
[0007] In a further embodiment, a user interface for interacting with reserves relevant data collected from reserves relevant data sources and being utilized for estimating reserves for an insurance carrier is provided. The user interface includes a predictive variable interface configured to display the reserves relevant data collected from the reserves relevant data sources, wherein the predictive variable interface displays the reserves relevant data over a selected time period. The user interface further includes a predictive model interface configured to display, over the defined time period, a predictive model performance and a predictive model variance for reserves estimates made based on the reserves relevant data over the selected time period.
[0008] In yet another embodiment, a non-transitory computer readable medium containing computer executable instructions for estimating reserves for an insurance carrier using a data platform configured to collect data from one or more source systems is provided. The computer readable instructions, when executed by a processor, cause the processor to perform steps including: collecting reserves relevant data from one or more data source systems over a system defined time period; converting the reserves relevant data into a reserves relevant data matrix, wherein the reserves relevant data matrix comprises a plurality of features based on the reserves relevant data that are organized based on the system defined time period; storing the reserves relevant data matrix at a reserves database of the data platform; executing a predictive model for each of the plurality of features of the reserves relevant data matrix to extrapolate a trend for each individual feature; and combining the trend for each individual feature to obtain a reserves estimate.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] FIGS. 1A and 1B provide an embodiment of a system schematic for determining cash reserves;
[0010] FIG. 2 provides an exemplary graphical comparison between different methods of predicting required reserves;
[0011] FIG. 3 provides a method of estimating reserves for a financial institution using the system of FIG. 1 ;
[0012] FIG. 4 provides an estimation of localized reserves modeling, according to an exemplary embodiment;
[0013] FIG. 5 provides a screen shot of a data visualization tool, according to an embodiment of the disclosure;
[0014] FIG. 6 provides another screen shot of the data visualization tool, according to an embodiment of the disclosure;
[0015] FIG. 7 provides another screen shot of the data visualization tool, according to an embodiment of the disclosure;
[0016] FIG. 8 provides another screen shot of the data visualization tool, according to an embodiment of the disclosure;
[0017] FIG. 9 provides another screen shot of the data visualization tool, according to an embodiment of the disclosure;
[0018] FIG. 10 provides another screen shot of the data visualization tool, according to an embodiment of the disclosure; and
[0019] FIG. 11 provides an electronic device according to an embodiment of the disclosure.
DETAILED DESCRIPTION
[0020] Embodiments of the disclosure describe a system for determining reserves an institution should have on hand to cover various operational challenges. A goal of the provided system is to utilize recent data combined with other data to increase granularity of information and apply a prediction methodology to the collected data to determine a reserve amount. In some embodiments, this system may be used in the medical insurance field. The medical insurance field will be used as an example in describing exemplary features of the system.
[0021] FIGS. 1A and 1B illustrate an embodiment of a reserves determination system 100 in the context of a medical insurance provider. FIGS. 1A and 1B illustrate an embodiment of a single system using two figures such that the system is more easily readable. For brevity sake, we will refer from here on to FIG. 1 , which is collectively meant to refer to FIGS. 1A and 1B as illustrating the reserves determination system 100 .
[0022] In FIG. 1 , information flow is shown to progress from Source Systems 104 to Data Platform 102 and then to Analytic Solutions 106 . Source Systems 104 may include, for example, information obtained from an Electronic Data Interchange (EDI), databases processing real time eligibility (RTE), call centers like Automated Systems Design (ASD), a Navigator for collecting member events, claims database (Claims dB), enterprise data warehouse (EDW), a membership database (AMRS), and Plan Design. Navigator is the institution's personal website where clients may make queries. Plan Design is a particular plan offered, which may include information relating to copayments, out of pocket maximums, coverage in and out of network, cost of emergency room (ER) visits, premium services, etc.
[0023] The Source Systems 104 may provide data relating to claims data, transactional data, pre-certifications, eligibility request, membership data, prescription data, benefits data, ASD calls, episodes of care, weather, care management, provider contracts, lab results, etc. Claims data may include claims paid and incurred within a timeframe. For example, claims data may include paid and incurred claims in the current month, claims paid and incurred one month ago, claims currently pending, and account payable (AP) held claims. AP held claims are claims held while information related to the claim is being investigated. The number of pre-certifications over a timeframe may be collected, for example, over the past 90 days. Pre-certification procedures are performed before certain activities to ensure a client or patient knows insurance coverage for procedures, and the data obtained during the pre-certification process may allude to future costs the insurance provider should anticipate. The number of eligibility requests over a period of time, for example, 15 days, may be obtained. All of this data may provide an indication of future claims, and, therefore, is useful for determining the amount of reserves the insurance provider should hold.
[0024] Membership data and benefits data may include age information, gender information, deductibles, out of pocket (OOP) maximums, co-insurance, etc. Prescription data and transaction data over a certain time period may provide insight to future costs. For example, number of new prescriptions in the past 28 days and the number of prescriptions in the past 28 days may be collected. Patient expenditure on transactions like non-prescription medication, other therapies, or over the counter diagnoses or monitoring devices may also be classified under transactional data collected. In certain aspects, information like bed days, that is, the number of days a patient is housed in a care facility is a lead indicator for predicting future expenditure. In other examples, episodes of care data which provide average episodes of care dollars are used as input data to the system. Episodes of care correspond to a collection of claims that are grouped together for certain conditions. For example, a heart attack or pregnancy may have a collection of claims for an episode of care. These episodes may be chronic or non-chronic as evidenced in the distinction between pregnancy and diabetes. In some instances, weather related information may be collected. These include road accident and ski accident data.
[0025] FIG. 1 shows example frequencies or time periods associated with the different information sources under Source Systems 104 . In addition to the different time periods, some show different modalities of achieving information transfer to the Data Platform 102 , for example, through Script or Sqoop. In the exemplary embodiment of FIG. 1 , Sqoop is used to input data into Apache Hadoop, and Script is used in general to depict customized scripts and modeling for the information flow.
[0026] Data Platform 102 provides an overview of the different modes of organizing the disparate data collected from the Source Systems 104 . EDI and databases storing RTE data provide eligibility data, for example, on a monthly basis and the information obtained is pooled as Eligibility 108 . Member events are provided by ASD and Navigator and processed through extracting, transforming, and loading (ETL) 110 the data to associate member activity with date information. This association creates a reserves relevant data matrix that contains the data from the ASD and Navigator systems organized as features and based on a system defined time period, such as the aforementioned date information. Member events may include phone calls, member online usage, etc. In some examples, members may search for a doctor or a specialist online using a computer or a phone, and this information may be an indicator of a future expense/claim since a specific doctor is being sought after. All of this data is then extracted, transformed and loaded by the ETL 110 into a plurality of features organized over the system defined time period into the reserves relevant data matrix.
[0027] Claims dB, EDW, and AMRS provide additional information about patient medical information. For example, claims data, pre-certifications, bed days, episodes of care, prescription data, and membership information may be combined with patient activity information, associating features provided with date or time information in another extracting, transforming, and loading (ETL) 112 . As such, in the illustrated embodiment, the ETL 112 combines the reserves relevant data matrix created by ETL 110 with data from the Claims dB, EDW and AMRS Source Systems 104 . This combination creates another reserves relevant data matrix containing the data from the various systems from Source Systems 104 organized over the system defined time period. Similar to the above description of ETL 110 , the reserves relevant data matrix created by the ETL 112 also organizes the data from the Source Systems (Claims dB, EDW and AMRS) into a plurality of features organized over the system defined time period.
[0028] The system defined time period can be set by a user of the Data Platform 102 . Further, this time period can be changed based on a desired collection of data to analyze. For instance, in one embodiment, a user may desire to collect and organize all reserves relevant data over a month, while in another embodiment, the user may desire to obtain all reserves relevant data over the past 10 days. As such, the system defined time period is variable and can be set over any time period desired.
[0029] The Data Platform 104 in the illustrated embodiment of FIG. 1 includes two ETLs 110 and 112 . However, in other embodiments, more or fewer ETLs may be utilized. For instance, a single ETL could collect and convert all of the reserves relevant data into a reserves relevant data matrix over the system defined time period. Additionally, several ETLs may be present, such as an ETL for each input from the Source Systems 104 , which in turn may feed any number of other ETLs for a chain of extracting, transforming, and loading of the data.
[0030] Returning to the illustrated embodiment, all of the Source Systems 104 data collected thus far and the pre-sorting and pooling of the data is further combined and stored in a Reserves database 114 . In some embodiments, the data stored in the Reserves database 114 is monthly data, while in other embodiments the data may be over a period of days. The Reserves database 114 then serves as a repository to supply a feature matrix that when coupled with statistical algorithms like linear regression provides reserve estimates that may be stored in the Reserve Estimates database 118 . In certain embodiments, instead of dealing with large databases, datamarts are used after combining collected data at different stages and extracting important features most relevant to estimating the reserves.
[0031] The different databases in Data Platform 102 are shown as separate databases, but these may be a single or distributed database physically housed at different locations. In some embodiments, Apache Hadoop is used for interfacing with Data Platform 102 , therefore Apache Hive infrastructure is used for data summarization, query, and analysis. In some embodiments, Spark with Scala may be used in addition to the Hadoop framework as shown in FIG. 1 where Eligibility 108 uses Spark and Scala for increased speed due to in-memory processing of large amounts of data.
[0032] The Reserves Model 116 in FIG. 1 serves to analyze, clean up, and organize data before storing the data in the Reserves Estimates database 118 (or in some cases datamart). In some embodiments, the Reserves Model 116 makes a prediction and stores the predicted results in the Reserves Estimates database 118 . The Reserves Model 116 makes its prediction based on reserves relevant data matrix from Reserves database 114 by applying a data modeling function to the various features collected and organized in the reserves relevant data matrix. In certain embodiments, this data modeling applies a predictive model that develops a trend and extrapolates that trend for each feature organized in the reserves relevant data matrix. The various trends developed for each feature are then combined to obtain the reserves estimate.
[0033] In a particular embodiment, each trend may be assigned a weighting value such that combination with other weighted trends, by the Reserves Model 116 , affects the overall combination determining the reserves estimate. In this manner, certain features can affect the reserves estimate more or less based on the assigned weight. The weight can be assigned per feature either automatically by the Data Platform 102 or via user input at a user interface at the Analytic Solutions 106 . The weight can be applied prior to determining the reserves estimate or post determination when already stored in the Reserve Estimate database 118 . For instance, in one exemplary embodiments, the trends utilized by the Reserves Model 116 may be a cumulative claims paid two months ago assigned a weight of 0.09069, a cumulative claims paid four months ago assigned a weight of −0.03864, a pending claims assigned a weight of 0.35105, claims waiting to be funded assigned a weight of 0.93229, claims waiting to be paid assigned a weight of 0.78372, eligibility requests assigned a weight of 7.78668, and approved bed days assigned a weight of −760.86141.
[0034] Examples of various data/predictive modeling functions are a linear regression, a non-linear regression, a support vector machine, a neural network, a decision tree, a random forest, or a time series analysis. The previous list is not exclusive, as other data/predictive modeling functions may be contemplated. Further, the Reserves Model 116 may apply its data model at various time periods, as requested by a user, or on a system defined/preset basis.
[0035] In some embodiments, the predictions include statistical reallocation of reserves based on new information, thus providing a feedback system between the Reserves Model 116 and the Reserves Estimates database 118 . In some embodiments, the Reserves Estimates database 118 is organized on a macro level, providing, for example, reserves needed for a certain territory like a country, such as the whole United States. In other embodiments, the Reserves Estimates are organized on a micro level, providing reserves needed for a certain region, like a state or local municipality. In other embodiments, a combination of regions or territories, for example, a grouping of countries or states. These may include reserve estimates for North America, Scandinavia, etc. or reserve estimates for the Northeast or Midwest, etc. In these embodiments, the data collected from Source Systems 104 is done so based on the desired region or regions. The ETL, such as ETLs 110 and 112 will further convert the data such that it is organized not just over the system defined time period but also per region/regions.
[0036] Additionally, in certain embodiments, the Reserves Estimates database 118 may be organized at the individual level. In these embodiments, data from Source Systems 104 may be collected at the individual member level in order to determine an amount of reserves apportioned to the individual member.
[0037] In FIG. 1 , after the Data Platform 102 , data flows from the Reserves Estimates database 118 towards Analytic Solutions 106 . Analytic Solutions 106 comprises modes of using or displaying information contained in the Reserves Estimates database 118 (embodiments of which are illustrated in FIGS. 5-10 ). For example, Analytic Solutions 106 may display estimated reserves data in Tableau or other data visualization products. In other embodiments, Analytic Solutions 106 may include creating Reserve Reports in Microsoft Excel or other programs. In some embodiments, a user of the report is able to use new market data to update information in the Reserves Estimates database 118 . For instance, new market data useful for updating information in the Reserves Estimates database 118 would be a change in deductible amounts, eligibility requests and other such data relevant to a certain market, such as healthcare.
[0038] Embodiments of the system thus provided create models at macro, micro, and even individual member levels. The models may be used to predict not just monthly but even daily reserves an institution may be required to hold for dealing with individual transactions. In some embodiments, the different reserves at different levels require different models in the Reserves Model of FIG. 1 . In some embodiments, the reserves for market sectors may be important as well in order to figure out reserve breakdown per sector/region.
[0039] Embodiments of the system may be used not just in the medical insurance field, but may be applied for pricing services. In other areas, the system may be used to detect an emerging epidemic in a geographic location based on several future indicators.
[0040] An exemplary embodiment that demonstrates how the system of FIG. 1 may be used by a medical insurance company will now be discussed. The insurance company may collect data pertaining to pre-certification, eligibility requests, episodes of care, claims, membership benefits, ASD calls, and prescription data. The insurance company receives this information from various sources, for example, through an information exchange and through direct interaction with health care providers or indirectly through patients or users on the insurance company's website.
[0041] The collected data is aggregated and stored in granular fashion. This means that the data, although aggregated, may be associated with and grouped at an individual member level. After collecting and organizing the data, certain algorithms, such as linear regression and/or other algorithms may be applied to the data. In some instances, the insurance company is able to rank the importance of each collected data or quality of the data based on the age of the data. For example, the insurance company may place more importance on data gathered two months ago relative to data gathered a year ago due to, for example, fluctuation in healthcare prices. The linear regression applied to the data provides information regarding the reserves required for the current model. This reserves information is stored in the Reserves Estimates database 118 of FIG. 1 .
[0042] FIG. 2 illustrates an example visualizing a reserves result when using the system of FIG. 1 to predict reserves required. The medical insurance company is able to generate data on a monthly basis, and applying different algorithms, the system of FIG. 1 is shown to provide a better estimate of actual claims and is shown to have lower variability than existing methods. The system of FIG. 1 uses a Data Science (DS) Model which is labeled as “1.” The claims data is starred and as can be shown, the other methods, labeled as “2” and “3” do not track the claims data as well as the system of FIG. 1 . The mean absolute error is the least for “1,” and the standard deviation is the lowest as well.
[0043] FIG. 3 illustrates a method of estimating reserves 300 for a financial institution using the reserves determination system 100 of FIG. 1 . At step 302 , the Data Platform 102 collects the reserves relevant data from the Source Systems 104 . At step 304 , the Data Platform 102 converts the reserves relevant data into a plurality of features organized over a system defined time period into a reserves relevant data matrix. At step 306 , the Data Platform 102 stores the reserves relevant data matrix at the Reserves database 114 . At step 308 , the Reserves Model 116 executes a data/predictive model for each feature of the reserves relevant data matrix to obtain a data trend for each feature. At step 310 , the Reserves Model 116 combines each extrapolated trend for each feature to obtain a reserves estimate over the system defined time period. As discussed above, in certain embodiments, at step 310 , the Reserves Model 116 also may apply a weighting factor for each trend prior to combining with other weighted trends. At step 312 , the reserves estimate is stored in the Reserves Estimate database 118 .
[0044] At step 314 , the Data Platform 102 (see FIG. 1 ) determines whether updated reserves and/or market data has been received. Updated reserves data would be additional reserves relevant data from the Source Systems 104 being utilized to supplement the reserves estimate stored in the Reserves Estimate database 118 . Updated market data is received from the Analytic Solutions 106 and may be utilized to update the reserves estimate based on the specific market data. For instance, an example of relevant market data may be a proportion of members in the relevant market, a historical claims volume in the relevant market or the types of insurance plans offered. If the Data Platform 102 determines that no updated reserves and/or market data has been received, then the Data Platform 102 does nothing, at step 316 . If the Data Platform 102 determines that updated reserves and/or market data has been received, then, at step 318 , the Reserves Model 116 updates the reserves estimate based on the updated reserves and/or market data. At step 320 , the updated reserves estimate is stored at the Reserves Estimate database 118 .
[0045] FIG. 4 illustrates an estimation of localized reserves modeling, according to an exemplary embodiment. FIG. 4 shows three charts, one illustrating a mean error comparison between two data models per various local markets/geographic regions. Another chart illustrates a max error comparison between the two data models per the same local markets. The third chart illustrates the cumulative membership of the financial institution (such as an insurance company) in the various local markets. These charts would be useful in determining a combination of various data types from the Source Systems 104 (see FIG. 1 ) and the type of predictive model utilized to give the best results in the reserves estimate. The percent error determination is determined by comparing actual reserves data from the past against a prediction made over the same time period.
[0046] Turning now to FIGS. 5-10 , various embodiments of the Analytic Solutions 106 (see FIG. 1 ) are illustrated. Each of these figures represents an embodiment of a user interface/data analysis tool embodied by Analytic Solutions 106 . Utilizing Analytic Solutions 106 , a user is able to review reserves estimate data from the Data Platform 102 and select and/or update the various models applied by the Reserves Model 116 and collected data from the Source Systems 104 . Further, the user may also provide updated market data to the Data Platform 102 as well as update any system defined time period over which data is collected in order to make a reserves estimate.
[0047] The Analytic Solutions 106 illustrated in FIG. 5 provides a comparison of three models: Pends, Completion Factor and Data Science. For each model, three curves are depicted in the charts on the left. The curve labeled “1” is an unadjusted restated reserves over a specified time period. The curve labeled “2” is an adjusted restated reserves over the specified time period. The curve labeled “3” is a comparison of one of the three models over the specified time period. The charts on the right side of the illustration represent the percent error between the adjusted restated reserves and the model. As can be seen, the Data Science model provides the least error between the adjusted restated reserves and the model prediction.
[0048] The Analytic Solutions 106 illustrated in FIG. 6 provides charts of various factors organized in the reserves relevant data matrix over the system defined time period. Each chart includes two curves: the curve labeled “1” illustrates actual data from the Source Systems 104 ; and the curve labeled “2” illustrates the predicted trend for that particular data from the Source Systems 104 that is used to formulate the reserves estimate. This embodiment of the Analytic Solutions 106 allows a user to view specific factor based data points utilized in the predictive models.
[0049] The Analytic Solutions 106 illustrated in FIG. 7 provides a collection of charts illustrating the most relevant factors/data collected from the Source Systems 104 (see FIG. 1 ). As illustrated, each chart shows a comparison between the data collected from the Source Systems 104 that is most relevant to predicting the restated reserves. Each chart shows a curve “1” that shows the restated reserves, and a second curve labeled “2” that shows data collected from the Source Systems 104 . Utilizing the Analytic Solutions 106 shown in FIG. 7 , a user is able to review the most relevant data collected from the Source Systems 104 . This data may allow the user to change and update various types of data to provide to the predictive models.
[0050] The Analytic Solutions 106 illustrated in FIG. 8 provides a comparison of claims data collected from Source Systems 104 . FIG. 8 shows two charts. The top chart illustrates a number of paid claims over a period of months. The bottom chart illustrates an amount of dollars appropriated for paid claims, pended claims, wait pay, and wait fund over a period of months.
[0051] The Analytic Solutions 106 illustrated in FIG. 9 provides three charts showing medical utilization. The chart on the top-left portion of FIG. 9 illustrates a percentage of members that have reached their deductible. Each curve illustrates the percentage of members to reach their deductible over a period of months during a certain calendar year—2014 and 2015, as illustrated. The chart on the top-right of FIG. 9 illustrates a cumulative number of bed days over a period of 50 days. The chart at the bottom of FIG. 9 illustrates an amount of paid claim dollars for three places of claim service: (1) outpatient, (2) inpatient, and (3) emergency. Each of these charts illustrates a type of data collected from Source Systems 104 and organized into features over a system defined time period in the reserves relevant data matrix, as discussed in relation to FIG. 1 .
[0052] The Analytic Solutions 106 illustrated in FIG. 10 provides a single chart that shows a predicted monthly change in reserves estimated using the previously discussed Data Sciences model. The chart shows a plurality of geographic locations and a shading that reflects a percentage change in reserves for the month for that specific geographic location. This chart is useful for determining how the reserves estimate is predicting an allocation of reserves for a plurality of local geographic regions.
[0053] FIG. 11 illustrates an electronic device 1100 according to an embodiment of the disclosure. Electronic devices, for example, servers and terminals comprising the Source Systems 104 , the Data Platform 102 and the Analytic Solutions 106 , in certain embodiments, may be computer devices as shown in FIG. 11 . The device 1100 may include one or more processors 1102 , memory 1104 , network interfaces 1106 , power source 1108 , output devices 1110 , input devices 1112 , and storage devices 1114 . Although not explicitly shown in FIG. 11 , each component provided is interconnected physically, communicatively, and/or operatively for inter-component communications in order to realize functionality ascribed to the various entities identified in FIG. Error! Bookmark not defined. To simplify the discussion, the singular form will be used for all components identified in FIG. 11 when appropriate, but the use of the singular does not limit the discussion to only one of each component. For example, multiple processors may implement functionality attributed to processor 1102 .
[0054] Processor 1102 is configured to implement functions and/or process instructions for execution within device 1100 . For example, processor 1102 executes instructions stored in memory 1104 or instructions stored on a storage device 1114 . In certain embodiments, instructions stored on storage device 1114 are transferred to memory 1104 for execution at processor 1102 . Memory 1104 , which may be a non-transient, computer-readable storage medium, is configured to store information within device 1100 during operation. In some embodiments, memory 1104 includes a temporary memory that does not retain information stored when the device 1100 is turned off. Examples of such temporary memory include volatile memories such as random access memories (RAM), dynamic random access memories (DRAM), and static random access memories (SRAM). Memory 1104 also maintains program instructions for execution by the processor 1102 and serves as a conduit for other storage devices (internal or external) coupled to device 1100 to gain access to processor 1102 .
[0055] Storage device 1114 includes one or more non-transient computer-readable storage media. Storage device 1114 is provided to store larger amounts of information than memory 1104 , and in some instances, configured for long-term storage of information. In some embodiments, the storage device 1114 includes non-volatile storage elements. Non-limiting examples of non-volatile storage elements include floppy discs, flash memories, magnetic hard discs, optical discs, solid state drives, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.
[0056] Network interfaces 1106 are used to communicate with external devices and/or servers. The device 1100 may comprise multiple network interfaces 1106 to facilitate communication via multiple types of networks. Network interfaces 1106 may comprise network interface cards, such as Ethernet cards, optical transceivers, radio frequency transceivers, or any other type of device that can send and receive information. Non-limiting examples of network interfaces 1106 include radios compatible with several Wi-Fi standards, 3G, 4G, Long-Term Evolution (LTE), Bluetooth®, etc.
[0057] Power source 1108 provides power to device 1100 . For example, device 1100 may be battery powered through rechargeable or non-rechargeable batteries utilizing nickel-cadmium or other suitable material. Power source 1108 may include a regulator for regulating power from the power grid in the case of a device plugged into a wall outlet, and in some devices, power source 1108 may utilize energy scavenging of ubiquitous radio frequency (RF) signals to provide power to device 1100 .
[0058] Device 1100 may also be equipped with one or more output devices 1110 . Output device 1110 is configured to provide output to a user using tactile, audio, and/or video information. Examples of output device 1110 may include a display (cathode ray tube (CRT) display, liquid crystal display (LCD) display, LCD/light emitting diode (LED) display, organic LED display, etc.), a sound card, a video graphics adapter card, speakers, magnetics, or any other type of device that may generate an output intelligible to a user.
[0059] Device 1100 is equipped with one or more input devices 1112 . Input devices 1112 are configured to receive input from a user or the environment where device 1100 resides. In certain instances, input devices 1112 include devices that provide interaction with the environment through tactile, audio, and/or video feedback. These may include a presence-sensitive screen or a touch-sensitive screen, a mouse, a keyboard, a video camera, microphone, a voice responsive system, or any other type of input device.
[0060] The hardware components described thus far for device 1100 are functionally and communicatively coupled to achieve certain behaviors. In some embodiments, these behaviors are controlled by software running on an operating system of device 1100 .
[0061] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0062] The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0063] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. | Embodiments of the disclosure provide a system and method of allocating a resource based on myriad input data. In some embodiments, the myriad input data include membership information, claims data, transactional data, etc. The myriad input data are sorted and organized in a meaningful association relationship before applied to a resource allocation modeling algorithm. The resource allocation modeling algorithm provides estimated resource necessary for the application chosen. For example, an insurance company may use membership information, claims data, transactional data, etc., to estimate how much reserves or funds it should hold to cover future claims within a certain timeframe. | 6 |
This is a continuation of co-pending application Ser. No. 07/566,659, filed on Aug. 13, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains generally to the field of reinforced concrete construction and in particular is directed to certain improvements in three-piece couplings for end-to-end splicing of concrete reinforcement bars.
2. State of the Prior Art
A reinforcement bar or, in trade parlance, a rebar, is a long cylindrical steel rod with surface deformations or ribs, the purpose of which is to impede turning or axial displacement of the rod when embedded in concrete. One typical rib configuration includes one or two continuous longitudinal ribs traversed by a plurality of spaced apart annular ribs. Various rib configurations and designs are in use, including oblique annular and helical ribs. A summary of rebar usage may be found at pages A1 through A5 in the appendix to the "Manual of Standard Practice" published by the Concrete Reinforcing Steel Institute (Jan. 1980).
Rebars have been in widespread use for many years as reinforcing elements in poured or cast concrete structures. In construction of large structures it is often necessary to splice together two or more such rebars end-to-end. This often occurs in large concrete form-work which is carried out in steps or stages. The reinforcing bars used at each stage must be joined to rebars for subsequent stages in order to achieve a monolithic concrete structure.
Many rebar splicing devices and couplers have been devised for this purpose. In so-called three piece couplers machine threads are cut or rolled in the ends of the rebars and an internally threaded sleeve joins two bars in an end-to-end splice. This general type of coupler has long been in use. In its most basic form, crude screw threads are cut into the irregular, ribbed surface at each end of a rebar, and two such ends are joined by a threaded cylindrical sleeve. The resulting joint tends to be loose and of low quality because of the rough-cut rebar threading. A better joint is obtained by removing the ribbing to make a smooth cylindrical surface before cutting the threads cut.
Variations of this basic scheme have been adopted in efforts to improve the quality of the splice. One approach is to create a conical taper at each end of the rebar which is then threaded. The threaded ends screw into a sleeve which has equally tapered internal threading, to provide a higher grade joint.
Still another approach has been to enlarge the rebar ends by upset forging or other means, before threading is cut or rolled into the enlarged cylindrical ends. The upset forging of rebar ends was disclosed by this applicant in U.S. Pat. No. 4,619,096 issued Oct. 28, 1986, which however relates to two-piece rebar splicing, in which one rebar end is hot forged to define an integral female threaded receptacle which mates to a male upset threaded rebar end to effect a splice joint. Two-piece couplings can be advantageous in certain applications because a separate coupler sleeve, i.e. a third (piece, is eliminated. In this applicant's prior patent, it is recognized that the upset ends prevent weakening of the rebar's tensile strength after the threads are cut into the enlarged ends. This is because the rebar ends are upset or enlarged in diameter before the threads are cut. This initial thickening of the rebar ends counteracts the effect of the subsequent cutting and prevents the rebars effective cross-section from being reduced by the screw threading.
The '906 patent disclosure is, however, limited to two-piece couplings and does not address the special advantages of upset threaded rebar ends when used in conjunction with a separate coupler sleeve in three-piece couplings.
A considerable shortcoming in conventional three-piece rebar couplings is the necessity to rotate at least one of the rebars about its longitudinal axis in order to make the splice joint. In the typical situation, one rebar may already be in place, embedded in concrete, with one end protruding. The coupler sleeve is then threaded onto the exposed end of the fixed rebar, and the rebar to be joined is then threaded into the free end of the coupler sleeve to make the splice. There are occasions however, when it is inconvenient or impossible to proceed in this manner. For example, it may be impossible to rotate a twenty foot long rebar bent to a right angle at a mid-point in a confined area.
This shortcoming results from the fact that, in conventional three-piece couplers, the coupler sleeve can only be threaded a limited distance onto the rebar, which distance is the length of the threaded portion of the rebar end. This length in turn is no more than can be accepted by the coupler sleeve, as it is undesirable for smooth machine threading to remain exposed outside the sleeve in the completed splice because this results in a weak rebar section of lesser net cross-section than the ribbed rebar body. Movement of the coupler sleeve beyond the threaded end portion is blocked by the surface deformations or ribbing of the rebar which rise above the thread edges and consequently beyond the inside diameter of the coupler sleeve.
Fatigue considerations and cyclic loading presently are not a factor in the construction codes applicable to the design of concrete reinforcement bars. This is changing however and, in anticipation of stricter design codes, the U.S. Government has tested currently used rebar splices under cyclic loading and fatigue conditions. It was found that all rebar splices now on the market fall short of the performance of an unspliced reinforcement bar. It was further found that an unspliced reinforcement bar has approximately a 50% chance of meeting the new cyclic loading standards being considered. Under the old standards for e.g. highway projects such as bridges which are subject to cyclic loading by heavy vehicles passing over these structures, a rebar was acceptable if it survives 2 million cycle of 10-12 thousand psi loading. It is anticipated that the new standards will require 5 million cycles at 30,000 psi.
The ability to achieve a rebar splice through rotation of the coupler sleeve exclusively depends on the ability of the coupler sleeve to move onto the ribbed area of the rebar, unimpeded by the raised rib deformations on the rebar surface.
In the past this has been achieved by "over threading" the rebar: a first machine thread on an upset end portion of the rebar continuing the thread cut over the adjacent ribbed section of the rebar.
Empirical testing has revealed however, that even a small cut or nick in the ribbing of the rebar produces a "cherpe" effect, by which stress force acting along the rebar is focused or concentrated by relatively minute changes in the geometry of the rebar. Even a shallow thread cut in the ribs has been found to create a plane of weakening in the rebar, and under protracted cyclic loading of the rebar as may occur for example, on a concrete bridge subject to heavy loads moving across it, creates a metal fatigue condition at the site of the surface cut which in turn eventually leads to structural failure of the rebar. Consequently, the expedient of extending the machine thread onto the rib deformations in order to allow the coupler sleeve to move onto the ribbed rebar area, sometimes referred to as double threading, is undesirable if a rebar splice is to approximate the performance of a continuous rebar.
For these same reasons, the three-piece coupler system described herein is preferable to a two-piece coupler system such as described in this applicant's prior Pat. No. 4,619,096 in applications where reliability under metal fatigue conditions is of concern. The elements in a three-piece coupling are straight cylindrical rods or sleeve with no abrupt changes in geometry, in contrast to the abrupt transition between the nominal rebar area and the enlarged integral end socket in the two-piece system.
SUMMARY OF THE INVENTION
According to this invention, the aforementioned difficulties can be overcome by upsetting the rebar ends sufficiently so that the end threading is of a diameter greater than the maximum diameter achieved at any point of the surface ribs. The enlarged diameter of the upset threaded portion can be achieved by hot forging of the rebar or any equivalent method. The inside end of the coupler sleeve can then be advanced onto the nominal rebar area, beyond the end threading, until the rebar end protrudes from the outside end of the coupler sleeve. This allows splicing of two rebars without necessity of axially turning either rebar. The second rebar is simply brought end-to-end with the protruding end of the fixed rebar and the coupler sleeve is turned in the opposite direction to bring it back over the joined rebar ends, thereby making the splice joint.
In a presently preferred form of the invention, the upset end of the rebar is enlarged to a diameter such that a coupler sleeve can be threaded beyond the male threads and clear the deformations on the ribbed area of the area. In other words, the bottom of the thread groove in the upset rebar end has a diameter at least slightly greater than the maximum diameter of the rib deformations. In another form of the invention, the rebar end is upset to a lesser degree such that the bottom of the thread groove does not exceed the maximum diameter of the rib deformations of the rebar. In order to allow the coupler sleeve to be moved beyond the upset threaded portion and onto the ribbed area, the ribs on a rebar segment immediately adjacent to the upset threaded portion are flattened by means of dies to a lesser height but without removing any significant amount of the rib material, so that the effective cross-sectional area of the rebar at the flattened portion remains substantially unchanged, thereby maintaining the tensile strength of the rebar.
A further improvement according to this invention is the provision of a pilot nose at the threaded end of the rebar. The pilot nose is an axial protrusion of reduced diameter which leads the threaded portion into the coupler sleeve, or other female threaded element, in order to facilitate the insertion and alignment of the mating threads. Because of the long length of the typical rebar, construction workers often have some difficulty in threading a second rebar into a coupler sleeve previously fitted on a fixed first rebar. The novel pilot nose ensures that, once it is inserted into the coupler sleeve, the male threads following behind it will be in proper axial alignment with the internal female threading of the sleeve. Proper engagement of the threads will then occur simply by then turning the rebar. Without the pilot nose, it is often a matter of several ineffectual attempts before proper engagement of the threads is achieved. The pilot nose is preferably a smooth cylindrical stub with a bevelled leading edge terminating in a circular end face of smaller diameter than either the cylindrical stub portion or the screw threads on the rebar, in order to facilitate entry of the pilot nose into the coupler sleeve or female coupling element being joined to the rebar.
Still another feature according to this invention is that the pilot nose is sized and configured so as to support a rebar vertically erect on a vertically aligned coupler sleeve or other female coupling, without engaging the threads of the rebar with those of the female element. The rebar can be left otherwise unsupported and free standing simply by inserting the pilot nose into a securely anchored female coupler. This is a useful feature in construction work since it allows the personnel to quickly set up a number of rebars and clear an area before individually twisting the rebars into the corresponding coupler element. Without provision of such a pilot nose, each rebar must be threaded into the coupling element before the worker can pick-up another rebar for placement into its socket or coupler. This pilot nose is useful not only with coupler sleeves but with any coupling element , socket or fixture having a threaded bore into which the rebar is to be mated.
These and other advantages and improvements of this invention will be better understood by reference to the following detailed description of the invention and attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a rebar end with upset threading and a pilot nose according to this invention:
FIG. 1a shows an alternate rebar end with upset threading but without a pilot nose;
FIG. 2 is a cross-section of the rebar taken along line 2--2 in FIG. 1 showing the normal ribbing height in the nominal rebar area;
FIG. 3 is a cross-section taken along line 3--3 in FIG. 3 showing ribbing flattened adjacent to the upset threaded portion of the rebar;
FIG. 4 is an axially exploded view showing a coupler sleeve between two upset threaded rebar ends;
FIG. 5 shows the elements of FIG. 4 joined to make a splice between the two rebars;
FIG. 6a illustrates how a bent rebar can joined to a fixed rebar without turning either rebar;
FIG. 6b shows a completed splice between the rebars of FIG. 6a;
FIG. 7a shows the pilot nose of the rebar leading the threading into a female fitting and supporting the rebar in free standing upright condition on the fitting;
FIG. 7b shows the rebar of FIG. 7a threaded into the female fitting.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, FIG. 1 shows one end of a concrete reinforcement bar or rebar 10 which has a basic cylindrical body 12 with an outer cylindrical surface 13 from which rise deformations or ribs 14 as best seen in the cross section of FIG. 2. The ribs 14 may take different shapes and in the illustrated example include two diametrically opposed longitudinal ribs 16 and axially spaced, crisscrossed pairs of oblique annular ribs 18 which intercept each other at the longitudinal rib 16.
FIG. 1 shows the left hand end of a rebar which is considerably longer than shown and terminates in an opposite, right hand end which may or may not be similar to the left hand end. In the typical rebar, both ends will be substantially similar and approximately mirror images of each other. Between the two ends is a long nominal rebar area, and which is characterized by the aforementioned rib deformations 14 on the cylindrical surface 13. The rib deformations 14 are hot rolled on an originally cylindrical rebar body in a manner well-known in the industry. Rebar lengths range to 60 feet or greater, with more typical lengths ranging between 20 and 40 feet. Shorter lengths are also used. Rebar diameters vary and are available in standard sizes which in the industry are designated by numerals in the range of 4 through 14, for the standard commonly used sizes. The height of the ribbed deformations 14 are typically 2/10 of the nominal rebar diameter.
According to this invention, an end segment 20 of the rebar has been enlarged in diameter by upset forging, and a machine thread 22 has been cut or rolled into the upset section 20. The extent of the upset i.e. the degree of diametric enlargement of the rebar along section 20 is such that the bottom 24 of the thread 22 has a diameter which is intermediate the diameter of the cylindrical rebar surface 12 and the maximum diameter achieved by the highest point of the rib deformations 14, including the longitudinal ribs 16 and the annular ribs 18. The height of the threading 22 above the thread bottom 24 will be determined by the thread size which in turn may relate to the diameter of the rebar, among other factors. The absolute dimensions of the thread 22 and upset diameter of section 20 consequently vary in proportion to the rebar diameter. The threaded upset section 20 of the rebar has a preferred length of one rebar diameter plus 1/4 inch.
The up-sized section 20 is formed by holding the hot rebar in a die which defines a cylindrical compartment surrounding an exposed three inch end segment of the rebar. An axial hydraulic ram strikes the still-hot end of the rebar with sufficient force and as many repetitions as needed to expand the exposed rebar segment to the diameter of the die chamber, shortening the exposed segment in the process. The machine thread 22 is then either cut or rolled on the up-sized segment 20.
The preferred extent of up-sizing of the end segment 20 is typically to a final diameter which is 1/8th of 1 inch in diameter greater than the nominal rebar diameter. The nominal diameter, a figure which is arrived at in a specific manner known in the industry, and given in Table 1 below for each rebar size, is approximately the diameter of the rebar body at surface 13, but may vary somewhat therefrom for certain rebar sizes. The rib deformations 14 in this area and, for the smaller rebar e.g. sizes 4-8, will rise to a maximum rib height typically less than the 1/8 inch up-sizing of section 20. This extent of up-sizing will allow an internally threaded cylindrical sleeve to be moved past the threaded end segment 20 and onto the ribbed area of the rebar without being obstructed by the deformations 16, 18.
As an alternative, particularly in the larger rebar sizes 9 through 14 in which substantial up-sizing is more difficult, a lesser enlargement of the threaded section 20 may be combined with a flattening or squeeze-down of the rib deformations 14 to a diminished rib height along a segment 25 of the nominal rebar area 12 adjacent to the up-sized section 20. This flattening can be accomplished, for example, by means of a hydraulic gripper arrangement including two semi-cylindrical dies configured to each cradle one longitudinal half of the rebar segment being treated. Two such dies are applied in diametrically opposed relationship to the rebar segment while the rebar is at hot forging temperatures with sufficient hydraulic force to achieve a flattening of the rib deformations 16, 18. Such hydraulic grippers are effective in reducing the height of the ribbed deformations without however, removing any significant amount of rebar material. As a result, the effective or net cross-sectional area of the rebar remains constant as illustrated in FIGS. 4 and 5. FIG. 4 shows the cross-section taken along line 4--4 in FIG. 1, where the rib deformations retain their original shape and height above the rebar body 12. In FIG. 5, the ribs have been flattened by means of the aforedescribed hydraulic grippers, resulting in rib deformations which are of reduced height and also somewhat spread out in a circumferential direction as compared to the original shape of FIG. 4. While the cross sectional shape is changed somewhat by this flattening, the net cross sectional area remains substantially unchanged, so that the tensile strength of the rebar is not impaired by this process.
__________________________________________________________________________ G (2) I J K D E F THD. H (3) NOMIN- OVER- LA B C COUP- STARTING O.D. CLR. THD. REDUC- AL ALL (1)BAR THREAD DRILL LER UPSET/ UPSET LGTH. CLR. TION BAR BAR MIN. AVG.SIZE SIZE DIA. OD ROLLED CUT REQD. DIA. REQD. DIA. DIA. HGT OF__________________________________________________________________________ D#4 5/8"-11 0.531 7/8" 0.568 0.625 1.000 0.527 0.035 0.500 0.562 0.020#5 3/4"-10 0.656 11/8" 0.687 0.750 1.125 0.642 0.045 0.625 0.688 0.028#6 7/8"-9 0.766 11/4" 0.805 0.875 1.250 0.755 0.120 0.750 0.875 0.038#7 1"-8 0.875 11/2" 0.921 1.000 1.375 0.875 0.125 0.875 1.000 0.044#8 11/8"-8 1.000 15/8" 1.046 1.125 1.500 1.000 0.125 1.000 1.125 0.050#9 11/4"-8 1.125 17/8" 1.171 1.250 1.625 1.125 0.125 1.128 1.250 0.056#10 1 7/16"-8 1.313 21/8" 1.359 1.437 1.813 1.302 0.135 1.270 1.438 0.064#11 1 9/16"-8 1.438 21/4" 1.484 1.562 2.208 1.427 0.198 1.410 1.625 0.071#14 17/8"-8 1.750 25/8" 1.796 1.875 2.250 1.740 0.135 1.693 1.875 0.085__________________________________________________________________________ NOTE: (1)THE MINIMUM AVERAGE HEIGHT OF DEFORMATIONS IS FOR EACH DEFORMATION. (2)THE LENGTH OF SQUEEZE DOWN GIVEN ALLOWS FOR THREADING THE COUPLER ENOUGH TO ALLOW DI'S TO TOUCH TIP TO TIP AND PILOTS WILL STILL FUNCTION. (3)THE REDUCTION REQUIRED FROM OVERALL BAR DIAMETER TO CLEAR THE COUPLER INSIDE DIAMETER
TABLE 1 lists presently preferred dimensions for the upset end threading, rib squeeze-down, and related data for rebar sizes 4 through 14.
Column B gives the thread size, in inches as well as in industry-recognized thread number. The thread numbers become smaller for larger sized threads. The thread dimension in inches indicates the diameter, A--A in FIG. 2, of the thread 22 from crest to crest in the upset threaded segment 20 in FIG. 1. Column D gives the drill diameter i.e., the thread diameter measured at the thread bottom 24 of section 20 in FIG. 1. This dimension corresponds to the crest diameter of the female threading in the coupler sleeve 40 of FIGS. 4 and 5.
Column C provides the outside diameter of the coupler 40 in FIGS. 4 and 5 for each rebar size. This is dimension B--B in FIG. 4. Columns E and F indicate the degree of diametric enlargement along the upset section 20 prior to formation of the thread 24: column E gives the outside diameter required for rolled thread 24, while Column F gives the same dimension for thread 24 which is cut instead of rolled. Column G gives the length of the rebar segment 25 in FIG. 1, adjacent to threaded segment 20, along which the ribbing 14 is squeezed down from the normal height C--C in FIG. 2 to a flattened condition C'--C' in FIG. 3, to allow the coupler sleeve 40 to be threaded onto this squeezed down ribbed area of the rebar, past the inside end of the thread 24. Column I gives the rib height squeeze-down reduction required i.e. the reduction from overall bar diameter required to clear the inside diameter of the coupler sleeve 40 for each rebar size.
Columns J and K respectively provide the nominal and overall rebar diameters along the ribbed portions of the rebar in FIG. 1 for each industry standard rebar size, while Column L gives the industry minimum average height of the deformations 14 above the cylindrical rebar surface 15.
The length of the squeeze down indicated in Column I allows threading of the coupler sufficiently over the ribbed area to allow two rebar ends to touch tip to tip, while retaining function of the pilot noses 30 on each rebar being joined.
In a preferred form of this invention, the rebar 10 has a pilot or lead-in nose 30 at each end, which is a cylindrical end stub extending axially from the upset threaded rebar segment 20. The pilot nose 30 is integral with the rebar 10 and is formed by hot forging, hot rolling or other convenient process. The nose 30 terminates in a circumferentially bevelled edge 32 and an end face 34. The cylindrical body 36 of the nose 30 has a diameter slightly lesser than the crest of the threading 42 on the female element to be screwed onto the rebar thread 22. In other words, the diameter of the nose is slightly lesser than the diameter at the bottom 24 of the rebar thread 22. The lead-in nose 30 may be omitted in an alternate form of this invention illustrated in FIG. 1a, which shows an alternate rebar 10, without the pilot nose 30 so that the upset thread 22 terminates in a blunt end face 44, but which is otherwise analogous to the rebar 10 of FIG. 1.
Turning now to FIG. 2, two rebars 10a and 10b each have an upset threaded end segment 20 and pilot nose 30 as described in connection with FIGS. 1, 4 and 5. The two rebar ends are shown on either side of a coupler sleeve 40. The sleeve is an internally threaded cylindrical tube open at both ends. The internal threading 42 is sized to mate with the rebar end threading 22. The sleeve is made of the same material as the rebars and preferably has an outside diameter (B--B in FIG. 4) such that the net cross-sectional area of sleeve 40 is at least 40% greater than the net cross-sectional area of the rebars. It has been found through empirical testing that this relationship between the coupler and rebar net cross sectional areas is critical to reliability of the splice joint in situations where metal fatigue must be taken into account. Metal fatigue occurs most commonly in structures which are cyclically stressed by heavy loads, such as bridges. The axial length of the coupler sleeve 40 is preferably no greater than required to fully admit the threaded end segments 20 of both rebars being joined as illustrated in FIG. 5. With this length, a worker can easily gauge that the sleeve is properly mounted to a rebar as soon as none of the threading of end segment 20 remains visible. This will be true regardless of which end of the coupler is threaded to either one of the rebars being joined.
An end-to-end rebar splice is made between rebars 10a and 10b by screwing the sleeve 40 onto the end of one rebar, e.g. 10a, and then screwing the end of the other rebar 10b into the opposite end of the coupler sleeve 40. A completed splice joint is shown in FIG. 5 where the threaded ends of both rebars 10a and 10b have been rotated into the coupler sleeve 40 until the threading 22 on each rebar is fully engaged with the internal threading 42 of the coupler sleeve 40.
Turning now to FIGS. 6a and 6b, is a situation is illustrated where one of the rebars, 10c is pre-bent to a right angle, as is common in construction practice. When the bent rebar 10c is to be engaged to rebar 10a which may have already been embedded in concrete (not shown) it will usually be found that rebar 10c cannot be rotated about the splice axis because of its length. This difficulty is easily overcome by threading the coupler sleeve 40 onto the end of the bent rebar 10c until a substantial portion of the sleeve 40 extends over the ribbed area 14 of the rebar, well past the up-sized threaded section 20. The exposed end of rebar 10c can now be brought end-to-end, or nose-to-nose, with the fixed rebar 10a and the coupler sleeve 40 then rotated back onto the end of the fixed rebar, to complete a splice joint as in FIG. 6b, without rotating either rebar in the process.
The pilot nose 30, aided by the bevelled edge 32 is useful in easily aligning a rebar into the open end of a coupler sleeve, a task which otherwise is not easy due to the considerable length and clumsy handling of the rebars once correct axial alignment has been achieved, threading of the rebar into the coupler sleeve is greatly facilitated in that cross threading of the rebar with the coupler sleeve is avoided. All of this translates into quicker handling and assembly of the rebars at the construction site which is directly reflected in time and cost savings.
The presently preferred length of lead-in nose 30 is one-half inch in length from the end face 34 to the transition 38 with the up-sized threaded section 20. The diameter of the nose 30 makes a close sliding fit with the crest of the thread 42 in the coupler sleeve 40. The close fit enables the rebar 10 to be left upright and free-standing on a female fitting 50 having an internally threaded bore 52 adapted to engage the rebar threading simply by sliding the lead-in nose 30 into the open end of the fitting. This is shown in FIG. 7a. The pilot nose 30 inserted in female threading 52 supports upright the rebar 10 without engagement between threads 22 and 52. In the case of larger rebars, a somewhat longer nose 30, e.g. 3/4 inch long, may be required to achieve this result. FIG. 7bshows the rebar 10 of FIG. 7a after threading rebar thread 22 into the female fixture 50.
From the foregoing, it will be appreciated that various improvements have been disclosed to facilitate the splicing or end-to-end coupling of concrete reinforcement bars in an expeditious and reliable manner. While particular dimensions and other details of the presently preferred embodiments have been described and illustrated for purposes of clarity and example, it must be understood that many changes, substitutions and modifications will be readily apparent to those individuals possessed of ordinary skill in the art without thereby departing from the scope and spirit of the present invention which is defined only by the following claims. | The threaded end of a concrete reinforcement bar is enlarged in diameter so that the thread bottom exceeds the diameter of the surface ribs of the rebar. A coupler sleeve can then be advanced past the end threading and over the rib area, until the rebar end protrudes from the coupler sleeve. This allows splicing of two rebars without axially turning either rebar. Alternatively, the thread bottom does not exceed the maximum diameter of the rib deformations of the rebar but an immediately adjacent rib segment is flattened without removing rib material to preserve the net cross-sectional area of the rebar and maintain the tensile strength of the rebar. A pilot nose of reduced diameter leads the threaded portion into the female thread to facilitate thread alignment and can support a free standing rebar on a female coupling before engaging the threads. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to a protective device for use for exterior prostheses, where the protective device is dimensionally conformed to the shape and size of the body or adapted to the contours of the anatomy of the person wearing the protective device, respectively.
BACKGROUND OF THE INVENTION
[0002] Exterior prostheses in the form of arm and leg prostheses are known in the art. They are made particularly from metals and/or carbon or other plastics and fibre materials. However, these materials do not lend themselves especially well to being worn when showering or pursuing water sports, because water, and particularly salt water, can attack and damage the very valuable, expensive materials of the prosthesis. Therefore, it is known to use “bathing prostheses”. These are made from plastics, but they do not have the advantages of the valuable metal or carbon prostheses, either with regard to wearing comfort or handling, the person who is wearing the bathing prosthesis can take a shower with it on or use it to walk to a body of water for recreation. It can even be worn for brief periods in the water, to cool down. But the disadvantage remains in that it usually must be removed for swimming and left on the bank at the point of entry into the water. In this context, the further problem arises in that in the case of rocky shores or unsupervised beaches, this is often not possible. Moreover, as the person in question removes the prosthesis, his handicap becomes evident to third parties and accordingly draws irritating attention to him. Since the design of such bathing prostheses usually is relatively unsophisticated, the prosthetic-wearing person is also prevented from getting to bodies of water that can only be reached by walking over rocks, stones and paths, because such routes usually do not offer a secure purchase.
[0003] Tubes are also known that are made from thin material and may be tightened on one side with a rubber drawstring or similar. In order to be able to adapt these to the anatomical shape of the person wearing the prosthesis or plaster cast, underpressure is created inside the tube. A valve and pumping bulb are provided in the skin of the tube for this purpose or another kind of device for producing an underpressure. Such a solution for sealing casts is especially known from AT 61218 E or from products of the company Dry Corp., LLC under the name Dry Pro™. Alternatively, it is known to use heat to fit it closely to the body of the person wearing the prosthesis or cast in the manner of a shrink tube. In either of these cases, the result is not very appealing. Moreover, if a valve with pumping bulb is provides, the problem arises that the valve may be damaged or opened during use later, and the sealing effect will be lost. In addition, swimming in bodies of water is rendered awkward because of the excessive amount of material. The short service life of these tubes or shrink tubes represents a further problem, since they can become damaged and start to leak very easily. In case of breakdown or malfunction of the valve or damage of the tube, respectively, an excessive amount of water will penetrate into the inner of the tube within a very short time. Moreover, the shrink tube variant can only be used once, and takes a great deal of effort to remove afterwards. This variant is thus a disposable product which is difficult to take off after use.
[0004] DE 41 25 635 A1 discloses a cover for a femoral or shank prosthesis and a method for producing the same wherein the cover is made of an elastic material with a closely tight surface such that the cover is watertight and water absorption is prevented. The cover is tube-like with a shape adapted to the limbs to be replaced. It can be fastened to the respective parts of the prosthesis with its both opening portions spaced from one another. Thus, only the prosthesis is watertightly sealed such that in principal some kind of bathing prosthesis is provided on the basis of a regular prosthesis. The transition from the upper prosthesis edge to the skin of the person wearing the prosthesis is, however, not watertight or protected against the penetration of water into the inside the cover or the prosthesis, respectively, such that water can penetrate into the same. Without the outside sealing the material of the cover is not watertight but will absorb water, since here a regular textile is pulled over the prosthesis and is sealed.
[0005] U.S. Pat. No. 5,593,453A discloses a prosthesis cover of a watertight latex material which closely conforms to the shape of the limb being covered. On the inner surface the cover has an anti-friction inner surface. Further, the cover has an anti-skid sole in the case of a leg cover. The anti-skid surface is provided with a plurality of inwardly directed ribs formed on the inner surface of the leg portion of the cover, the plurality of ribs being spaced apart from each other with each rib extending concentrically of the leg portion. The plurality of ribs extends from just above an ankle portion throughout the height of the leg portion to just an upper segment to space the cover from the prosthesis and to thereby reduce the frictional engagement when the cover is being applied by sliding over the prosthesis. At the outside the cover has finger loops for enabling the pulling on and off which finger loops will negatively affect the aesthetic of the cover and cannot provide the impression of a human skin.
[0006] The object of the present invention is therefore to overcome the problems mentioned with regard to the known protective devices and to create a device to replace both the bathing prosthesis and vacuum or shrink tubes as well as the above mentioned protective devices which enables the wearer to shower and swim safely, and to participate fully in beach life actively and without attracting undue attention, wherein the penetration of water and foreign bodies, respectively, like sand, dirt, dust, into the inside of the protective device can securely be prevented.
SUMMARY OF THE INVENTION
[0007] The object is solved for a protective device for use for exterior prostheses in that the protective covering is made from an at least semi-elastic, waterproof or watertight or custom-designed sufficiently preventing water from penetrating the inside of the protective covering resilient and durable and damage-resistant material, and has a cuff or sleeve or collar like at least semi-elastic device at one end thereof the dimensions of which are adapted to the contours and size of the anatomy of the person wearing the protective covering to prevent water or moisture or foreign bodies from penetrating into the protective covering. Refinements and advanced embodiments of the invention are defined in the dependent claims.
[0008] Accordingly, a protective device for use for exterior prostheses is created that is worn as a protective covering over a conventional prosthesis. In this way, it serves as protection therefore, since it is thus possible to effectively prevent water and foreign bodies from penetrating the prosthesis and, thus, damaging the prosthesis by penetrating water or penetrating foreign embodiments, like especially sand, can be effectively avoided. The term watertight means waterproof and splash water resistant and water resistant as well as moisture proof. The feature of a custom-designed sufficient obviation of a penetration of water into the protective covering means that dependant on the respective use the protection by the material of the protective device as well as the protective device itself is made such that the entrance of water or moisture into the protective device can be avoided. The material of the protective device thereby is watertight, the construction of the protective device as well as its treatment especially with regard to the connection area of the material is custom-designed or with regard to the respective use avoids the penetration of water into the protective device. Hereby, especially splash water but also water during a shower or bathing can be prevented from entering the inside of the protective device. Therefore, the cuff or sleeve or collar like at least semi-elastic device is provided which provides a secure bearing of the protective device on the skin of the person wearing the prosthesis by optimally adapting its shape to the body part next to the prosthesis where the protective covering holds tightly on. By this shape adapting combined with the at least semi-elasticity the protective device adheres optimally onto the skin of the person wearing the protective device. The protective covering according to U.S. Pat. No. 5,593,453 A only has a conically shaped upper end portion which is, however, made as one part with the rest of the protective covering. No cuff or sleeve or collar like device is, thus, added contrary to the present invention, where the device is made of a material providing a very good bearing on the extremity stump which device is made of at least semi-elastic material. So, the prosthesis is optimally protected against damages by the material of the protective covering and the prosthesis is further optimally protected against damages by penetration of water, moisture, foreign bodies etc. by the sleeve or collar of cuff like at least semi-elastic device attached to the rest of the protective covering such that the device and the rest or main body of the protective covering can be made of optimal materials each being attached to one another. Thus, the prosthesis is optimally protected in every aspect.
[0009] By the use of an at least semi-elastic material, that is to say a material of which at least a part has elastic properties, and which is adapted to the contours of the body, the protective device fits closely, at least at the pertinent points, against the extremity stump to which the prosthesis is attached, and possibly also against the prosthesis, so that the protective device remains in the desired position, this alone helping to prevent penetration at least by dirt such as dust, but also by sand. The dimensional conformation to the shape of the body is understood to mean dimensional conformation to the anatomy of a person, not necessarily a specific person, but generally to the shape and size of human bodies. Mass production is possible in this context, but so is individual adaptation to a specific person, of course. In mass production, the protective device may offered in various sizes, reflecting the differing anatomies of people, some of whom may be taller or stouter, according to the same principle that is applied for clothing in different sizes. In this way, an adaptation to the body of the person wearing the protective device may also be made visually, which represents an aesthetic advantage over the tubes of the prior art, which cannot be adjusted dimensionally to the body shape, but are instead significantly oversize, and accordingly hang over the anatomical shape of the person like a cloth, particularly in the area of a person's arm or leg, after shrinking or removal of the air.
[0010] Using a durable, damage-resistant material helps to prevent cracks from forming when the protective device is used, which would allow water and foreign bodies to enter the inside of the protective device. A durable, damage-resistant material is understood to be material that is relatively tear-resistant, and thick enough not to rip for example if it scrapes on stones or other hard objects in passing. In this context, durable means that the material is capable of withstanding stresses without suffering any, or at least essentially any damage, particularly without ripping. In this context, damage-resistant particularly means that the material may only be separated by deliberate cutting, but is otherwise stable enough to protect the person wearing the protective device from the entry of moisture or foreign bodies. Watertight non hydrophilic materials such as chloroprene rubber, polychlorophene rubber or chlorobutadiene rubber, thus, foamed rubber materials, have proven to be particularly suitable for this purpose. Latex material is not understood to be a damage-resistant or durable material. The materials mentioned in the prior art, such as latex, do not show the desired stability and durability. Especially an easy moving and sporting at the beach or any gardening is not possible with these kinds of protective devices. Further, the protective devices according to the prior art may not be combined with bathing shoes worn over the protective devices. This means an essential disadvantage since the normal prosthesis has an ankle which is always set in a specific angle dependent on the desired heel height. Without a shoe the leg may be brought automatically and inadvertently into a hyper extended position. In such a position someone can do swimming without any problems. When he wants to run or walk this is not possible without any risk when he does not wear shoes which wearing of shoes is possible with the protective device according to the present invention and which is, however, not possible with the protective devices according to the prior art as cited above. Walking or running along the beach, especially sporting, as well as gardening is, thus, not possible without any difficulty with protective devices according to the prior art.
[0011] Of special advantage is a cuff or sleeve or collar like device which is added to the material provided for the rest of the extension of the protective device which is, thus, added as a sleeve or collar to the end side of the protective device. By this cuff or sleeve or collar like device it is possible to provide the inner surface of the cuff or sleeve or collar like device directed to the inside of the protective device with an adhesive effect or with an adhesive, respectively. A penetration of humidity or moisture or water is securely avoided by use of the sleeve or collar like device. The device is furnished with an opening. This is usually at least the opening through which the wearer slides the protective device on, that is to say the end of the protective device that subsequently lies against the extremity stump. Since the device is dimensioned so as to conform to the wearer's anatomy, it fits particularly closely against the extremity stump, which already helps to prevent water and foreign bodies, especially dust, from getting into the protective device.
[0012] The cuff or sleeve or collar like device may include a long-lasting elastic material with adhesive effect, particularly latex and/or silicone, and/or a material having a smooth surface with adhesive property. Simply by virtue the material's elasticity, as already mentioned, the cuff or sleeve or collar like device already lies very close against the wearer's skin adjacent to the prosthesis, which also provides good protection against penetrating moisture but also against the entrance of dust. Unlike a shrink tube, the protective device may also be removed very easily after use, and may, thus, be used repeatedly.
[0013] As has been described, the protective device is made at least in part from a chloroprene rubber, polychloroprene rubber or chlorobutadiene rubber. The side of the chloroprene, polychloroprene or chlorobutadiene rubber that is intended to lie against the skin of the wearer may be provided in the end or side area or in the area of the sleeve or collar like device of the protective device, which is shaped so as to cover the prosthetic wearer's skin, with a smooth surface having adhesion properties, designed as smooth skin Neoprene® for example. Providing such a border or selvage or designing the device with such cuffs that are attached to rest of the material of the protective device also serves as a further measure for preventing water from getting inside the protective device when this border or cuff or sleeve or collar like device fits tightly against the skin of the person wearing the prosthesis.
[0014] The device shaped as a selvage or shaped as an attached sleeve or collar having a wedge of silicone or latex may be provided to create good grip on the skin of a person wearing the protective device. The device also may be made of silicone or latex material. Since the device advantageously has an adhesive effect, thus an adhesive or gluing effect, a very good and tight sticking on the skin surface of a person is possible by such an adhesive effect.
[0015] To achieve particularly good waterproofing and a much better sticking on the skin surface of a person, in this area, a skin adhesive may be applied to the smooth border area of the protective device that has adhesive properties, i.e. the cuff like or sleeve like or collar like device. This may be a liquid or have the form of a double-sided adhesive tape or another form of an adhesive. It is applied to the end on the inside of the protective device that is designed as the protective covering, in other words the side intended to contact the person's skin, where an opening is provided for putting on and taking off the protective covering. When the protective covering is shaped like a long stocking for protecting a leg prosthesis, the device and the skin adhesive are advantageously provided in the area in which the protective covering is in contact with the prosthetic wearer's skin.
[0016] Alternatively to applying skin adhesive, or possibly in addition to such application, a separate, cuff-like covering element made from a waterproof material or a material preventing the penetration of water, particularly silicone and/or latex, may be provided. This may cover both the border area of the protective device and the skin of the person wearing the protective device, thus providing protection against penetration particularly by moisture and water and dust. A material having an adhesive effect can be printed e.g. to the outside of the cuff or sleeve or collar like device provided at the end of the protective device, so that a watertight connection is possible by overlapping the sleeve or collar like device by the cuff-like element. Thus, attaching the protective device to the skin of the prosthetic wearer adhesively or providing the cuff-like element in this way helps to reliably prevent water and foreign bodies from getting inside the protective device, even while pursuing various types of water sport. Providing a latex or silicone cuff to form the end of the protective device's border, that is to say either as a border edge or sleeve or collar like device previously attached to the protective device or as a separate covering element, is able to create a waterproof attachment to a person's skin even without using a skin adhesive.
[0017] The unfurling effect of the end side boarder area, thus the boarder portion, or the cuff of sleeve or collar like device during the wearing by a person can be avoided by sticking the device to the person's skin. Further, it is possible to provide the device with at least one device preventing the unfurling movement. The same can be built as at least one pocket like unfurling preventing device with at least one stick like reinforcing insert. The pocket like unfurling preventing device can be applied onto the material of the protective device, e.g. in the form of an ironed material patch, when provided as a rubber material or being applied adhesively or in another way when coated with an adhesive material. For providing a stiffening or reinforcing effect in order to avoid any unfurling movement of the edge or boarder portion of the protective device at least one reinforcing insert is inserted, e.g. in the form of a stick, in the pocket like unfurling preventing device. By the subsequent inserting it is possible to withdraw the reinforcing insert for cleaning the pocket like unfurling preventing device. Alternatively, it is possible to provide at least one reinforcing device which is not removably fixed onto the material of the protective device.
[0018] Here it should be emphasized that the providing of a skin adhesive, of a separate cuff like covering element or of an unfurling preventing device advantageously provides additional components which are not necessary for the protective device. By use of these additional components the water tightness may be increased for specific cases of operation or use, where larger forces impact the protective device and result in a releasing effect of the protective device with regard to the skin surface of the person wearing the same. This effect may for example appear during diving or if the body shape in the area of the extremity stump of the person wearing the protective device is distinctively conical.
[0019] It is further advantageous if the protective device is constructed in multiple layers. In this case, the protective device may include at least one foam layer, for example a layer of foam chloroprene rubber, polychloroprene rubber or chlorobutadiene rubber. To ensure a sturdy, easy to handle surface, at least one side of the protective device is also furnished with a surface coating, in particular it is laminated. Such a surface coating or lamination may be provided on one or both sides, that is to say on the outside and/or the inside of the protective device. In all cases it is also possible not to provide any surface coating or lamination. Suitable materials for such surface lamination particularly include lycra and nylon, which are particularly applied as a woven surface.
[0020] The selvage or the sleeve or collar like device of the protective device may be made from a chloroprene rubber, polychloroprene rubber or chlorobutadiene rubber, which may be laminated or unlaminated. This is advantageously made from smooth skin Neoprene® on the side facing towards the person wearing the protective device, and in this context it has a lamination on one side and is unlaminated on the other side and has a smooth surface of chloroprene rubber, polychloroprene rubber or chlorobutadiene rubber to show the intended adhesive effect directed to the skin of the person wearing the protective device. If a selvage or a sleeve or collar like device, respectively, of silicone and/or latex is provided, this advantageously has the form of a cuff in solid material. If technically possible, the cuffs may also be laminated on the side facing away from the person wearing the protective device. The device for protecting against wet and moisture and for preventing penetration by dust, sand and dirt may thus have the form either of a cuff made particularly from the materials described above and be connected to the rest of the material of the protective device or affixed thereto, or it may be conformed directly with the rest of the material of the protective device or fitted onto it.
[0021] The abutting points of the protective device material may be essentially sealed to make them watertight, particularly by sewing, welding or adhesion. A mixture of these joining methods is also easily possible, The material used to manufacture the protective devices may have a material thickness from 0.5 mm to 5 mm, for example, particularly from 1 to 3 mm. This lends the protective device very good stability combined with sufficient but not excessive rigidity, while still retaining all possible dimensional stability. When a thin material is used for the protective device, that is to say precisely with chloroprene rubber, polychloroprene rubber or chlorobutadiene rubber, such material may be butt welded and the weld seam may be covered with corresponding strips. In this way, the abutting points may be rendered sufficiently waterproof and durable even when a thinner material is used. Besides the foam layer, other material layers may also be provided, which are joined together one on top of the other to create the material of the protective device. For example, the outer layers may also be provided using materials that are highly abrasion-resistant and for example resistant to seawater.
[0022] In addition, at least one material or material patches that increase friction may be provided on the sole area of a foot, ensuring good grip when the wearer is walking over rocks or other slippery surfaces. The sole is thus rendered non-slip by design, particularly by coating.
[0023] The sealed construction of the protective device itself and its close fit against the skin of the person wearing the prosthesis, particularly if no adhesion is applied there and no separate cuff-like covering element is used, serves to effectively keep out of the protective device's inside not only water, but also sand and dust of course, thus also successfully preventing the prosthesis from being damaged. Accordingly, it is not necessary to use additional waterproofing means or means to prevent dust and sand from getting in.
[0024] The protective device may be designed in the manner of a sleeve or legging with integral hand or foot element. It is also possible to design the protective device as a tubular arm or leg covering without a hand or foot element. If the hand or foot element is created integrally with the protective device, particularly secure protection is provided against penetration by water or moisture, since then only one opening must be securely closed and sealed. In the case of a tubular protective device that has however been adapted dimensionally to fit the person wearing it, and in which the hand or foot of the person wearing the prosthesis protrudes out of the protective device, two openings are provided in the protective device, and these are located and particularly secured by adhesion at the wrist or ankle, that is to say in the area of the hand or foot of the person wearing the prosthesis, and in the area of the shoulder or thigh or hip of the person wearing the prosthesis.
[0025] The protective device may also be designed as a one-legged trouser-like covering incorporating the form of the body part or the torso of the person wearing the protective device. Such a design is particularly suitable for people who only have very short stumps in the area of their extremity, making it almost impossible to affix the protective device securely there. For this purpose, the protective device is then designed as a trouser-like covering of a covering incorporating the form of the torso, so that it may be affixed elsewhere on the body and not at the extremity stump. In this case too, an adhesive material or skin adhesive or a respective cuff or sleeve or collar like device may be applied to the respective openings where water or moisture, or also dust and sand might enter, in order to provide waterproofing or at least to make it difficult for water, moisture, dust, sand and foreign bodies to get in.
[0026] In terms of appearance, the protective device may be adapted to the normal skin colour of the wearer, or it may be coloured differently. Contrary to the prior art this is possible and will lead to a result having a very good appearance. Conventional methods such as silk-screen printing, or also lacquering and airbrushing may be used to colour the material. The natural colour of a laminating material, which may be in a variety of colours, may also be used on the side of the protective device that faces outwards, that is to say away from the wearer. The material used for the protective device may also be dyed in all cases.
[0027] The protective devices may be cut into shaped panels from a chloroprene rubber, a polychloroprene rubber or chlorobutadiene rubber, and subsequently joined at their abutting points, for example by sewing, adhesion or welding. The lamination or coating is applied to the base material or along the abutting points of the material panels of the sleeve and legging shapes where applicable before joining. A coating may be or may have been applied to both sides or also to just one side, so that in the finished legging or sleeve shapes a coating is provided only on the outside, or only on the inside, of on both the outside and the inside, by placing another material layer over the top of it, or laminating over it. The material specification or design, that is to say its colour, the material used one-sided or double-sided lamination or coating, one-sided smooth surface and so on, may be incorporated in the base material, that is to say in the yard goods or when the panels are cut. One layer of a foam chloroprene rubber, polychloroprene rubber or chlorobutadiene rubber for example, such as are marketed under the Neoprene® brand by DuPont for example, is provided as the middle layer in a multilayer construction of the protective device. However, it may also be prepared as the only layer. Accordingly, the possible construction variants are such having only one semi-elastic and essentially water impermeable material layer, such having a lamination or coating only on the outside, that is to say facing away from the person wearing the protective device, such having a lamination or coating only on the inside, that is to say facing towards the person wearing the protective device, and such having both an inner and outer coating or lamination. A solid material mad from a material having adhesive properties, such as latex or silicone, may be provided for the selvages or cuffs. The base material of the protective device may also be designed with a smooth surface on the inside, facing towards the person wearing the protective device, in which case in particular an outer lamination or coating may also be provided. Not only the base material, but also the selvages or cuffs or sleeve or collar like devices may be prefabricated and merely cut to size according to the intended application before they are joined to the rest of the protective device material.
[0028] In the case of injured limbs, water sports and visits to the beach are avoided to protect the wound from exposure to moisture and dirt. To enable the injured person to actively participate in beach activities, and even pursue water sports despite this, a protective device for protecting limbs against contact with moisture, and particularly foreign bodies such as dirt, includes furnished with a protective covering made from an at least semi-elastic, water impermeable or custom-designed sufficiently preventing the inside of the protective device from the penetration of water, resilient and damage-resistant material and that has been adapted to conform to the body size and shape and at least one end of which is equipped with a cuff-like, sleeve like or collar like device having a size and anatomically conformed shape for preventing penetration by water or moisture and foreign bodies. The devices may be or have been constructed in the same way that the device described previously for protecting an exterior prosthesis.
[0029] The present protective device thus has the advantage with regard to known bathing prostheses in that it is very much smaller and easier to handle, which is a significant advantage, particularly when travelling. An extra bathing prosthesis does not need to be included in luggage, only the small, folding protective device, which fits into luggage like any normal item of clothing. Moreover, it is not necessary to bring a pumping bulb or a heat radiating device for shrinking protective devices so that they lie flush against the wearer's skin, and this is also an important advantage over the tube-like protective devices according to the prior art, which are only available in standard sizes. These advantages may be enjoyed not only when travelling but during any other leisure activities, particularly in recreational sport, since here too the protective device may be carried in a sports bag much more easily than other protective devices, such as bathing prostheses above all but also such tube-like devices that must be shrunk or require means for creating a vacuum. Also with regard to the other above mentioned protective devices according to the prior art the protective device according to the present invention is more comfortable during use, thus, also during its pulling on and off as well as during maintenance and cleaning. Also, any necessary repairs can be done much easier since on one hand the multilayer material can be better repaired and on the other hand the cuff or sleeve or collar like device can be much easier and better changed or repaired when being deteriorated or damaged because of the attachment of the cuff or sleeve or collar like device to the rest of the protective device.
DESCRIPTION OF THE DRAWINGS
[0030] In the following text, embodiments of the invention will be described in greater detail, with reference to the drawing for detailed explanation thereof.
[0031] In the drawing:
[0032] FIG. 1 a is a side view of a first embodiment of a protective device according to the invention for use for arm prostheses,
[0033] FIG. 1 b is a side view of a variant of the embodiment of the protective device of FIG. 1 a,
[0034] FIG. 2 a is a side view of a second embodiment of a protective device according to the invention for use for an arm prosthesis,
[0035] FIG. 2 b is a side view of a variant of the embodiment of the protective device of FIG. 2 a,
[0036] FIG. 3 is a side view of an embodiment of a protective device according to the invention for use for a leg prosthesis,
[0037] FIG. 4 is a side view of a further embodiment of a protective device according to the invention for use for a leg prosthesis,
[0038] FIG. 5 is a side view of a seventh embodiment of a protective device according to the invention for use for an arm prosthesis,
[0039] FIG. 6 is a side view of an eighth embodiment of a protective device according to the invention for use for a leg prosthesis,
[0040] FIG. 7 is a side view of a ninth embodiment of a protective device according to the invention for use for an arm prosthesis, in the form of a protective covering that incorporates the upper body,
[0041] FIG. 8 is a side view of a tenth embodiment of a protective device according to the invention for use for a leg prosthesis, in the form of a trouser-like protective covering.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIGS. 1 a and 1 b show embodiments of a protective device 1 in the form of a “sleeve”, that is to say a protective covering for an arm prosthesis. The protective device is furnished with an arm section 10 and a hand section 11 with a finger section 12 , which is shown fully with clearly illustrated fingers in the embodiment in FIG. 1 a, but only indicated or reproduced as a mitten in the embodiment in FIG. 1 b. The finger section covers the fingers of the hand prosthesis like a glove, just as the hand section of protective device 1 covers the rest of the hand prosthesis. The arm section covers both the arm portion of the prosthesis and a part of the extremity stump of the person wearing the prosthesis, that is to say it fits closely against the skin. This close fitting against the skin occurs at least at the upper arm end area 13 . At least the inside of this area is provided with an adhesive material or consists of such an adhesive material to provide watertightness and ensure a good grip in this area. For example, protective device 1 has a cuff or sleeve or collar like device 130 , for example in the form of an affixed cuff in upper arm end area 13 . It can be made from latex and/or silicone. Another smooth surface having adhesive properties may also be provided here directed to the extremity stump, thus, on the inside of the protective device 1 or the cuff or sleeve or collar like device 130 . If a material other than latex and/or silicone is used for upper arm end 13 , if necessary a wedge-shaped insert or an insert made from latex and/or silicone may be provided and this significantly increases grip on the extremity stump and skin of a person wearing the protective device. Otherwise, the material of the protective device or the cuff or sleeve or collar like device 130 has a degree of elasticity at least in the area of the arm section adjacent to the upper arm end and in the upper arm end area so that it is able to lie particularly snugly and tight against the extremity stump, and is able to create a tight closure against the skin of the person wearing the prosthesis.
[0043] FIGS. 2 a and 2 b show a second embodiment of a protective device 1 in the form of a sleeve, this embodiment being very similar in principle to the embodiment shown in FIGS. 1 a and 1 b. Unlike that embodiment, however, the protective device 1 of FIGS. 2 a and 2 b does not have an upper arm end with affixed latex and/or silicone. Instead, inside of the upper arm end in the form of a cuff or sleeve or collar like device 130 , facing towards the person wearing the protective device, is provided with a smooth surface having adhesive properties, particularly produced from a smooth skin Neoprene®. The upper arm end may be attached to the rest of the material of the protective device or it may be produced as an integral part thereof. In order to ensure waterproofing when lying on the skin of a person wearing the protective device 1 , a skin adhesive 131 may additionally be applied to the smooth surface, which already has inherent adhesive properties, thus enabling a particularly secure and tight connection with the skin of the person wearing the sleeve. This variant is used particularly when smooth skin Neoprene® is provided, but it may be used equally well with an attached silicone cuff. A silicone material can advantageously be used especially for people who react on latex material or are allergic with regard to latex material. It should be noted that an additional waterproof seal is assured by just a latex or silicone cuff such that no further means are necessary for providing a protection against the penetration of water, especially in case of a desired splash water protection.
[0044] Instead of a skin adhesive, a cuff-like covering element 132 may be pulled over the selvage of the protective device and the wearer's skin to provide good protection against penetration by moisture and water and dust or dirt. Such a covering element is shown in FIG. 2 b by broken lines. For a specific watertight connection the protective device may be provided with an adhesive material in the area of the upper arm and on the outside 133 , e.g. in the form of a printing 134 . This is indicated in FIG. 2 b.
[0045] For use for a right and left arm, either the same protective devices 1 or correspondingly adapted, differently conformed protective devices may be provided. Coatings may be provided to improve anti-slip characteristics particularly on the palm, and optionally in the area of the finger sections. This enables the person wearing the prosthesis to support himself on the prosthetic hand if necessary without fear of slipping over, particularly on wet and therefore slippery surfaces.
[0046] FIG. 3 shows protective device 1 in the form of a “legging” for pulling over a leg prosthesis. This protective device is designed analogously with protective device 1 shown in FIGS. 1 a and 1 b, but is provided with a leg section 14 and a foot section 15 . Instead of an upper arm end 13 , hear a thigh end 16 is provided, which also ensures protection against penetration by water and foreign bodies, if necessary even without use of a skin adhesive. For this purpose, the thigh end also has a surface having adhesive properties in the area of the cuff or sleeve or collar like device 130 . This consists in particular of a long-lasting elastic material with adhesive effect. As for upper arm end 13 , thigh end 16 may also often be realised as a separate element and attached to leg section 14 or arm section 11 . Thigh end 16 is made for example from latex and/or silicone or it has a corresponding insert made from latex and/or silicone. It is also possible to apply an adhesive coating or lamination to the thigh end or upper arm end in the area of the cuff or sleeve or collar like device 130 on the side thereof facing the skin of the wearer, or to use a material with corresponding adhesive properties, particularly smooth skin Neoprene®.
[0047] Such an alternative embodiment to the embodiment of a legging of FIG. 3 is shown in FIG. 4 . The legging shown here differs from the embodiment of FIG. 3 only in that a smooth surface having adhesive properties, particularly a smooth skin Neoprene®, is provided in the thigh end area or the area of the cuff or sleeve or collar like device as an inner surface, that is to say facing towards the person wearing the protective device. The thigh end may be attached to the rest of the material of the protective device as a cuff, or it may be produced integrally therewith. Is for the embodiment of FIGS. 2 a and 2 b, a skin adhesive is also used here, ensuring a much better watertightness when it is applied to the skin of the person wearing the prosthetic. Otherwise, watertightness may also be assured simply by providing a wedge insert made from latex and/or silicone. A further alternative to this embodiment consists in providing a separate cuff-like covering element 135 , made from latex and/or silicone for example. This is pulled over the border of the protective device and over the skin of the person wearing the protective device, and is thus able to prevent particularly moisture and water and dust and dirt from penetrating the protective device as just mentioned above with regard to FIGS. 2 a and 2 b. Like there an additional sealing by for example printing an adhesive material onto the outside 136 of the protective device in the form of a printing 137 in the area of the thigh end is possible here (at least indicated in FIG. 4 ). To avoid an unfurling of the thigh end a number of pocket like unfurling preventing devices 180 with rod or stick like reinforcing inserts 181 is applied there. The reinforcing inserts 181 can be removed for cleaning such that the pocket like unfurling preventing devices 180 are open at one side. They can also be totally closed such that the removing of the reinforcing inserts is no longer possible. The reinforcing inserts 181 can also be directly applied to the material of the protective device in the area of the thigh end, for example they can be sewn on or stitched in there. However, no removing of the sticks or rods is possible then.
[0048] In the embodiments of the protective device shown in FIGS. 3 and 4 , both soles 17 of the two leggings may be furnished with an anti-slip coating 170 . Particularly on wet and slippery surfaces, this is able to provide better grip for the prosthesis wearer.
[0049] Since the sleeves in FIGS. 1 a, 1 b and 2 a, 2 b are each shown with an attached or integral hand section 11 and finger section 12 , the hand and finger sections of protective device 1 are not shown in FIG. 5 . This protective device is simply tube-shaped like arm section 10 . However, this embodiment also has an upper arm end 13 with a cuff or sleeve or collar like device 130 exactly like the embodiment of FIG. 1 . In addition, a wrist end 18 is also provided in the wrist area of the arm prosthesis to create a seal. As before, upper arm end 13 is advantageously made from a long-lasting elastic material with adhesive effect, particularly latex and/or silicone or provided with a material having adhesive effect and optionally a skin adhesive to create a seal sealing against the penetration of water with the skin of the person wearing the prosthesis. Since wrist end 18 lies flush with the prosthesis surface, so that the prosthetic hand is uncovered, a sealing end is created with the surface of the prosthesis in the area of wrist end 18 , and a long-lasting elastic material with adhesive effect may be advantageously used here too.
[0050] FIG. 6 shows a corresponding legging design without a foot section. In this case, the prosthetic foot of the person wearing the this prosthesis is uncovered, and the legging has an ankle end 19 in the area of the ankle of the prosthesis. Thus, protective device 1 as shown in FIG. 6 only includes one leg section 14 with a thigh end 16 at one end, and accordingly there are two openings, which are in watertight contact with the skin of the person wearing the prosthesis and also with the prosthesis itself. Here too, long-lasting elastic materials with an adhesive effect may be provided, particularly as a solid material, for example latex and/or silicone, in the area of the thigh end and the ankle end, in the form of cuff or sleeve or collar like devices 130 .
[0051] The two opposite ends of both the sleeve of FIG. 5 and the legging of FIG. 6 may also be provided only with a smooth surface having at least a small amount of adhesiveness, and may be affixed to the skin or the surface of the prosthesis in watertight manner by adhesion with the aid of a skin adhesive. However, the provision of an adhesive material that is able to function without the use of an adhesive is more suitable, particularly in the area close to the prosthesis, since the adhesive would have to be removed from the prosthesis without causing it any damage when the protective device is removed. Accordingly, the use of materials, such as latex and silicone, for example, which have inherent adhesive qualities, and which can be removed from the surface of the prosthesis without residue and without attacking the prosthesis, is advisable. For this reason, a cuff-like covering element made from latex and/or silicone that is arranged to cover the respective selvage of the protective device and the uncovered prosthesis is most suitable.
[0052] FIG. 7 shows a further embodiment of a protective device 1 , which in this example is configured as a protective covering incorporating the upper body. This example is similar in shape to a pullover in which the sleeve on one side is conformed to a hand section, but there is no second sleeve. Thus, protective device 1 has a torso section 20 , an arm section 21 and a hand section 22 with finger section 23 . The arm prosthesis arranged on the side of arm section 21 , hand section 22 and finger section 23 may thus be fully covered and protected. Especially when the extremity stump is too short to allow a protective device to be attached securely here, attachment is assured in such manner that very good attachment to the body of the person wearing the prosthesis is possible via torso section 20 . The healthy arm protrudes through a corresponding arm opening 24 in the torso section. Torso section 20 is also furnished with a neck opening 25 and a bottom opening 26 facing towards the abdomen. Cuff or sleeve or collar like devices or elements for protecting against penetration by water, moisture and dirt are advantageously provided in the area of these three openings 24 to 26 , particularly a long-lasting elastic material having an adhesive effect on at least one side, such as smooth skin Neoprene® or latex or silicone as solid materials, wherein material coatings or laminations having adhesive properties may be applied to another material. It is also possible to use for example a chloroprene rubber, polychloropene rubber or chlorobutadiene rubber with a smooth, adhesive surface, in which case a skin adhesive may be applied additionally here as well to provide a watertight seal in the area of openings 24 to 26 .
[0053] FIG. 8 shows a corresponding counterpart to the embodiment for the arm prosthesis in the form of a protective device 1 constructed in the manner of a single trouser leg for a leg prosthesis. One leg of this trouser-like protective device is then designed in the manner of a pair of tights, while the other only extends with a thigh section 27 over a portion of the healthy thigh of a person wearing a one-sided leg prosthesis. The leg prosthesis is accommodated completely in the leg section 28 conformed in the manner of one half of a pair of tights. The leg section is also furnished with a foot section 29 . In this manner, it is possible to fully enclose the leg prosthesis, thus ensuring reliable protection for the leg prosthesis even if the extremity stump is too short at the thigh to allow a protective device as shown in FIG. 3 or 4 to be attached securely thereto.
[0054] The two remaining openings 30 , 31 in the thigh section and in the area of the thigh of the person wearing the protective device may also be conformed variously to provide a watertight seal, and in particular cuff or sleeve or collar like devices 130 made of a long-lasting elastic material having adhesive properties and having a smooth surface with adhesive properties may be provided, and may optionally be affixed to the skin surface of the person wearing the protective device using a skin adhesive. It is also possible to provide for example a cuff made from latex and/or silicone.
[0055] A design that is conformed to the body shape of the person wearing the protective device is particularly advantageous especially in the embodiments shown in FIGS. 7 and 8 , since when the material is lying very closely against the person's skin, the desired sealing effect may be assured, and the person is also not impeded unnecessarily by the protective device.
[0056] Many other shapes may be created besides those shown, particularly also combination shapes of the variants illustrated. In particular, the two embodiments of FIGS. 7 and 8 may also be realised without a hand section or a foot section respectively, that is to say they may be equipped correspondingly with a wrist end or ankle end. In any case, it is advantageous to provide a secure attachment to the body of the person wearing the prosthesis in order to protect the valuable prosthesis from damage, particularly caused by penetrating dust, sand and water, especially seawater. An injured arm or leg may also be protected from contact with moisture and foreign bodies by a protective device of such kind.
[0057] Chloroprene rubber, polychloroprene rubber or chlorobutadiene rubber, particularly in the foam forms, are suitable materials for the protective device, and the material of the protective device may also be created using multiple layers as indicated e.g. in FIG. 6 . In this case the layer 171 of foam material may be provided particularly effectively as the inner material layer, while other material layers 172 , 173 having greater resistance to wear are arranged above and below it. Layers of such kind may be made from lycra and/or nylon or other wear-resistant materials. The cut material panels are joined by sewing, adhesion, welding, or by some other process to form a sealed protective device. A seam 32 of such kind is indicated in FIGS. 5 and 6 . The surface of the protective device may be dyed, in particular to match the skin colour of the individual wearing the prosthesis. A lamination or coating may also be coloured. It is even possible to simulate body hair with colouring methods.
[0058] Besides the embodiments described above of protective devices for use for exterior prostheses, many other embodiments may also be created, in which the protective device in each case is a protective covering made from an at least semi-elastic, watertight or essentially watertight, or resistant to water penetration or splash water or waterproof, durable, tear-resistant and damage-resistant material that is dimensionally conformed to the shape of the body, and at least one end of which is furnished with a cuff or sleeve or collar like at least semi-elastic device the dimensions of which are conformed to the body shape of the person wearing the protective device so that water or moisture and foreign bodies are unable to penetrate. The elastic device especially adheres to the person's skin and prevents penetration of water or moisture or dirt or dust, respectively, or foreign bodies into the inside of the protective device.
[0059] While in accordance with the patent statutes, the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.
REFERENCE NUMERALS
[0000]
1 Protective device
10 Arm section
11 Hand section
12 Finger section
13 Upper arm end
14 Leg section
15 Foot section
16 Thigh end
17 Sole
18 Wrist end
19 Ankle end
20 Torso section
21 Arm section
22 Hand section
23 Finger section
24 Arm opening
25 Neck opening
26 Lower opening
27 Thigh section
28 Leg section
29 Foot section
30 Opening
31 Opening
32 Seam
130 cuff or sleeve or collar like device
131 Skin adhesive
132 covering element
133 outside
134 printing with adhesive material
135 covering element
136 outside
137 printing
170 Anti-slip coating
171 layer of foamed material/inner material layer
172 upper material layer
173 lower material layer
180 pocket like unfurling preventing device
181 stick rod like reinforcing insert | People who wear a prosthesis currently have to use a bathing prosthesis if they wish to pursue water sports or take a shower or reach a body of water for recreational purposes and take active part in beach pursuits safely. However, these are usually taken off for swimming though this is very often not possible in the case of rocky shores or unsupervised beaches, quite apart from the unwelcome attention to which the person wearing the prosthesis is sometimes exposed in doing so. To solve this problem, a protective device for use for exterior prostheses is suggested, in which the protective device is a protective covering made from an at least semi-elastic, durable and damage resistant material being watertight or custom-designed sufficiently preventing a penetration of water into the inside of the protective covering and being dimensionally conformed to the shape of the body, and at least one end of which is furnished with a cuff or sleeve or collar like semi-elastic device that is dimensionally adapted to the contours of the anatomy of the person wearing the protective covering to prevent water or moisture or foreign bodies from penetrating the protective covering. This is particularly convenient and easy to carry and use when travelling and for recreational sport. | 0 |
RELATED APPLICATION(S)
[0001] This application is a Continuation in Part of and claims priority from U.S. patent application Ser. No. 13/250,828 that was filed on Sep. 30, 2011, and that is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The term “timber” as used herein refers to wood suitable for use in the construction of a building or the like. Several main types of wood construction are generally known. These types use various forms of timber from logs to sawn/shaped timbers to smaller branches and leaves. These types also utilize various types of wall coverings from plant-based coverings to timber materials to earthen materials, such as mud or stone. A first type of wood construction is thatch construction, which is generally a traditional construction type. Other types include post-and-beam frame construction, walls with bamboo/reed mesh and post (waffle and daub), wooden frames with or without infill, and stud-wall frames with plywood/gypsum board sheathing. Two other types are wood panel construction and log construction.
[0003] The origin of log building construction is uncertain. The first log structures are thought to have been built in Northern Europe about 3500 BC. Early techniques involved stacking tree trunks on top of each other and overlapping the corners resulting in some of the first log cabins. The strength of log structures was improved with interlocking corners made by notching the logs near the ends and overlapping the log in the notches. Such interlocking corners brought the logs closer together making it easier to seal the structure against the weather by stuffing the spaces between logs with moss or other materials.
[0004] Logs used in construction are often peeled of their bark. When using younger logs with a significant taper over length, such logs may be hewn to reduce the taper. Logs may also be hewn or otherwise cut to make them square or rectangular instead of round. Traditionally, round log building were often considered temporary until a more permanent structure could be built. But square log craftsmanship is considered the original permanent home design. Some advantages of square log over round include:
[0005] Square logs are from the heart of a tree where shrinkage is minimal (typically less than 1 inch) as opposed to round logs with shrinkage of up to 5 inches. Thus, dealing with log shrinkage is much easier when using square logs.
[0006] Square logs can be fitted to better avoid water problems and associated rot than round logs. This results in longer building life. For example, square log homes over 500 years old are said to be common in Europe.
[0007] Square logs can easily be drilled for wiring and plumbing runs between courses while round logs, due to their shape, require chases or other methods of hiding wires and plumbing.
[0008] Unlike square logs, round logs tend to catch dust due to their shape. Round logs also make interior decorating more difficult due to their shape. Square logs, on the other hand, tend to be much easier for people to live with and keep clean. The term “square log” as used herein generally refers to a log or beam or timber or the like, composed of natural wood or any other material or combination of materials suitable for building construction, of some length, sections of which are substantially and consistently rectangular in shape, where one example of rectangular is square. Note that conventional square logs are made from natural wood and are typically fabricated as a single piece out of tree trunks.
[0009] For these advantages and more, modern log buildings built with square logs tend to enjoy a higher appraised value than round log buildings. In fact, the larger the square logs, the higher the value—and the cost. One reason for this is that square logs are generally cut from the heart of a tree and larger trees for making larger square logs tend to be scarce and expensive.
[0010] In recent times, log buildings have become increasingly popular for vacation cabins and even for homes. Various building techniques are combined to make such homes appealing and attractive. As a result, there is an increasing interest in and demand for log buildings and the timbers required to construct them. At the same time, the availability of old-growth timber suitable for producing larger logs is increasingly scarce and expensive.
SUMMARY
[0011] The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the invention nor does it identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some general concepts in a simplified form as a prelude to the more detailed description that is presented below.
[0012] The detailed description discloses techniques for building construction using fabricated timbers. In one example, such timbers are fabricated using conventional 2× (two-by) lumber to produce a square log appearance. These fabricated timbers are then stacked to form outside and/or inside walls such as for a building. The fabricated timbers and walls are configured to sustain the vertical and lateral loads anticipated for a building such as a cabin, house, garage, barn, office building, or the like. A building constructed of such timbers appears to be built of square logs. Variations provide for chinking between courses of timbers, or for timbers stacked without chinking. The height of each log course can be as little as a few inches to well over a foot or more. With one variation, the height of a log course can appear to be several feet or more. The terms “stacked” and “stacked one atop another” and the like as used herein typically refer to multiple objects (e.g., fabricated timbers) where one such object is placed on the bottom, and another such object is placed on top of the bottom object, and so forth until a top object is placed on the top of the stack of objects, thus forming a vertical stack of the multiple objects.
[0013] The disclosed techniques can be used with any type of building foundation including crawl space, slab-on-grade, and full basement, and with any type of roof structure. Further, construction using pre-manufactured fabricated timbers requires far fewer steps over conventional log and stick frame structures, as illustrated in Table 1 below.
[0000]
TABLE 1
Fabricated
Conventional
Stick-Frame
Construction Steps
Timbers
Logs
& Stucco
Stack
A
B
Frame
X
Exterior sheathing
X
Fabricate utilities chases
C
Wire
X
X
X
Plumb
X
X
X
Insulate
X
Seal
X
Sheet rock
D
E
X
Tape
X
Mud
X
Sand
X
Texture
X
Interior molding
X
X
X
Interior prime
X
Interior paint
X
Vapor barrier
X
Chink
X
X
Windows
X
F
X
Doors
X
F
X
Exterior molding
X
X
X
Netting
X
Stucco
X
Stain/paint interior/exterior
X
X
X
moldings
[0014] In Table 1, an ‘X’ indicates a required construction step. Table 1 indicates that construction based on fabricated timbers takes far fewer steps than conventional stick-frame construction (and is thus correspondingly less labor intensive), but is also simpler and less labor intensive that conventional log construction. The various letters other than ‘X’ indicate the following:
A: stacking can be performed by two or three people without the use of heavy equipment such as a crane. B: stacking requires the use of heavy equipment such as a crane. C: Fabrication of chases for wiring and plumbing and the like in conventional log construction is very labor intensive and costly. This expensive step is not required when using fabricated timbers. D: Due to very limited shrinkage of walls made of fabricated timbers (made from kiln dried lumber, typically less than 1″ for a 10′ wall), such walls can be wall-boarded if desired several months after construction. E: Due to significant shrinkage of conventional log walls (typically several inches for a 10′ wall), wall-boarding is generally not possible. F: Due to significant shrinkage of conventional log walls (typically several inches for a 10′ wall), installation of doors and windows requires extra-large cut-outs to accommodate shrinking over time, and may require adjusting moldings over time to account for shifting due to shrinkage.
[0021] Further, the R-value achievable by fabricated timbers typically ranges from 2.5 to 4 per inch of wall thickness, depending on the insulating material used inside and the height of the fabricated timber. For example, a fabricated timber using a 2×12 wood horizontal member typically provides an R-value of about R-40. In general, the taller each timber is in a wall, the greater the R-value provided by the wall. Further, taller and wider timbers tend to be more desirable because they can be made to have the appearance of tall and wide conventional logs which are very desirable due to the scarcity and high cost.
[0022] In addition, insulating materials that can be used in fabricated timbers may range from straw to conventional fiberglass wool, shredded paper (cellulose), or any other material that can provide a desired R-value, thus providing relatively low-cost, high-R-value walls. On the other hand, a conventional square logs typically provide an R-value of less than 2 per inch of log thickness. And a conventional 2×6 stick-frame wall typically provides approximately R-value of about 20. Thus, given fabricated timber construction, buildings that are far more heat-efficient can be easily and inexpensively constructed that also use far fewer materials and construction steps than conventional stick-frame construction, and at significantly lower cost and higher thermal efficiency than conventional log construction, yet with the high appraised values of high-quality conventional log construction. The term “R-value” as used herein is a conventional term that typically refers to the capacity of a material to resist heat flow.
[0023] Many of the attendant features will be more readily appreciated as the same become better understood by reference to the following detailed description considered in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0024] The present description will be better understood from the following detailed description considered in connection with the accompanying drawings, wherein:
[0025] FIG. 1 a is a diagram showing an end view of an example fabricated timber.
[0026] FIG. 1 b is a diagram showing a 3-dimensional view of an example fabricated timber.
[0027] FIG. 2 a is a diagram showing a top view of an example fabricated timber.
[0028] FIG. 2 b is a diagram showing an end view of the example fabricated timber.
[0029] FIG. 3 is a diagram showing an example of an example wall constructed from a plurality of fabricated timbers.
[0030] FIG. 4 is a diagram showing an example of a method for constructing a fabricated timber.
[0031] FIG. 5 is a diagram showing an example of a method for constructing a wall from fabricated timbers.
[0032] FIG. 6 a is a diagram showing an end view of an example alternate fabricated timber.
[0033] FIG. 6 b is a diagram showing a 3-dimensional view of example alternate fabricated timber.
[0034] FIG. 6 c is a diagram showing an example of incorporating housewrap in a fabricated timber.
[0035] FIG. 6 d is a diagram showing an example of sealing the adjoining reveals of two stacked fabricated timbers.
[0036] FIG. 7 is a diagram showing an example of a wall constructed from a plurality of example alternate fabricated timbers.
[0037] FIG. 8 a is a diagram showing an example of a tall fabricated timber.
[0038] FIG. 8 b is a diagram showing an example of another tall fabricated timber.
[0039] FIG. 9 is a diagram showing an example of construction of a single-reveal fabricated timber that has the appearance of a tall solid wood timber on one side and a reveal on the other side.
[0040] FIG. 10 is a diagram showing an example of construction of a single-reveal alternate fabricated timber that has the appearance of a tall solid wood timber on one side and a reveal on the other side.
[0041] FIG. 11 a is a diagram showing front and side views of an example of a fabricated timber end cap.
[0042] FIG. 11 b is a diagram showing front and side views of an example of another fabricated timber end cap.
[0043] FIG. 12 is a diagram showing an example method 1200 for dressing joints of a fabricated timber, etc.
[0044] Like reference numerals are used to designate like parts in the accompanying drawings.
DETAILED DESCRIPTION
[0045] The detailed description provided below in connection with the accompanying drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present examples may be constructed or utilized. The description sets forth at least some of the functions of the examples and/or the sequence of steps for constructing and operating the examples. However, the same or equivalent functions and sequences may be accomplished by different examples.
[0046] Although the present examples are described and illustrated herein as being implemented for building construction, the techniques described are provided as examples and not limitations. As those skilled in the art will appreciate, the present examples are suitable for application in a variety of different types of construction or the like.
[0047] FIG. 1 a is a diagram showing an end view of an example fabricated timber 100 with a 3-dimensional view of the same example fabricated timber 100 shown in FIG. 1 b . Such a timber according to this example is typically fabricated with two vertical members (e.g., members 110 and 120 ) of thickness t v and height h disposed on a horizontal member (e.g., member 130 ) of thickness t h and width w, each of the three members having substantially the same length l. In one example, the length l of the various members is from one to thirty feet, the height of the vertical members is from three to fifty inches, the width of the horizontal member is from three to thirty inches, and the thickness of the various members is from one to four inches. In other examples, the lengths l of the members may vary from one another, as may the thicknesses t v of 110 , t v of 120 , and t h of 130 . The surface measured by height h of the vertical members (e.g., 110 and 120 ) may represent a vertical plane of the members, and the surface measured by width w of the horizontal member (e.g., 130 ) may represent a horizontal plane of the member. The term “substantially” as used herein typically indicates “according to plan”, “nominally”, “conventionally”, and “customary” in relation to the arts of house-scale building construction as known to those of average skill in the art. The term “from n to m <units>” as used herein (e.g., from one to thirty feet) typically refers to a specific measurement based on a particular unit of measure (e.g., feet or inches or the like) that is ≧n and ≦m. For example, eight feet is a distance in feet that is from one to thirty feet. Thirty-nine feet, on the other hand, is not from one to thirty feet.
[0048] One vertical member 110 is typically disposed length-wise atop the left side L of horizontal member 130 , and the other vertical member 120 is typically disposed length-wise atop the right side R of horizontal member 130 , as illustrated in FIG. 1 b . Vertical members 110 and 120 typically have substantially the same height h. Each vertical member (e.g. 110 and 120 ) sits atop the horizontal member (e.g., 130 ) such that its height h is at an angle that is substantially perpendicular to or at a substantially 90 degree angle to the width w of the horizontal member (e.g., 130 ). The length l of supported vertical member 110 typically extends down the length l of horizontal member 130 , and the length l of supported vertical member 120 also typically extends down the length l of horizontal member 130 . Vertical members 110 and 120 are typically disposed length-wise atop horizontal member 130 so as to be substantially parallel with each other (e.g., 160 ), and to be substantially parallel with outer sides L and R of horizontal member 130 . In one example, the shape of each member may generally be described as cuboid comprising three opposing pairs of rectangular faces. A conventional 2×4 stud, for example, is substantially cuboid in shape. A conventional sheet of plywood, for example, is also substantially cuboid in shape.
[0049] In some examples, vertical members 110 and 120 are fastened to horizontal member 130 using fasteners (e.g., 150 ) such as nails, screws, bolts, staples, pins, dowels, pegs, spikes, ties, strapping, adhesive, or the like. In one particular example, fastener 150 represents conventional 16d nails every n inches on center. The term “every n inches on center” as used herein refers to a fastener (e.g., a nail) installed so as to fasten the vertical member to the horizontal member as illustrated in FIG. 1 a , with such a fastener installed at least every n inches along the length l of the vertical and horizontal members, each such fastener approximately centered between the inner vertical face F i of the vertical member (e.g., 110 and 120 ) and the outer vertical face F o of the horizontal member (e.g., 130 ). One example of n may be 8. In other examples, other types or sizes of fasteners may be installed at other increments along the length l of the vertical and horizontal members. In further examples, a fabricated timber may be cast, extruded, molded, hewn, carved, cut, milled, or otherwise fabricated as a single piece rather than fabricated of separate members 110 , 120 , and 130 as shown in the examples of FIGS. 1 a and 1 b.
[0050] Note that the horizontal and vertical members of a fabricated timber form a channel 180 . This channel may be used for installing utilities such as electrical wires, gas and/or water lines, ducting, and the like. This channel may optionally be filled with insulation. Blocking may be added at the ends to keep insulation in, or ends may be covered with plastic, cardboard, or any other suitable material or the like to retail any insulation inside the fabricated timber. The term “blocking” as used herein typically refers to pieces of wood or other material (e.g., 224 ) disposed between members (e.g., 110 and 120 ) to provide support, attachment sites, or brace against lateral-torsion buckling, or the like.
[0051] The composition of fabricated timbers (e.g., 100 ) as described herein is not limited to wood, but may be plastic, fiber-cement, metal, laminated materials, composites, or the like, or any combination of such. In one example, conventional 2× lumber has been shown to be an inexpensive and readily available choice of materials that is simple to work with and that only requires commonly-available skills and tools. The term “2× lumber” or “two-by lumber” as used herein generally refers to softwood or conifer sized to nominal standardized dimensions as commonly used in construction of wood-buildings and the like, where the number ‘2’ in “2×” typically refers to the nominal pre-dried 2-inch thickness of the lumber which typically measures about 1.5 inches once dried. Such 2× lumber used in the construction of fabricated timbers and the like is typically kiln dried or the like. Note that other types and sizes of lumber may also be used in fabricated timbers, including hardwood, rough-cut wood, or wood of thicknesses less than or greater than about 1.5 inches, etc. The only factor limiting the composition of a fabricated timber 100 is that it should possess certain attributes as described herein below.
[0052] In the example where members 110 , 120 , and 130 are each separate members, one attribute that these members should possess is a common shrinkage characteristic. The term “shrinkage characteristic” as used herein refers to expected amounts and directions of shrinkage over time and/or under particular conditions for a particular material (e.g., wood, etc.). Further, should the material from which members (e.g., 110 , 120 , and 130 ) are fabricated include a grain (as with e.g., wood, fiber-cement, etc.), the grain of each member should be oriented in substantially the same plane, such as a horizontal plane. Such grain alignment may result in shrinkage over time that is relatively consistent in direction and amount between each of the members. Further, any given member (e.g., 110 , 120 , and 130 ) may actually comprise multiple separate members of various lengths positioned end-to-end resulting in an overall length of l. The term “grain” as used herein typically refers to an overall direction of a pattern of fibers or the like of a material such as that from which members of a fabricated timber are comprised.
[0053] The term “fabricated timber” as used herein refers to a statutory article(s) of manufacture constructed according various example methods described herein and that is configured for possessing various attributes specified herein. The term “fabricated timber” does not refer to any pre-existing article(s) of manufacture or the like. Nor does it suggest any pre-existing method(s) of construction or the like.
[0054] In one example of a fabricated timber 100 , a vertical member (e.g. 120 ) is disposed atop a horizontal member (e.g., 130 ) such that the outer portion of the vertical member overhangs the horizontal member resulting in a reveal, such as reveal r 140 . Either or both vertical members may be disposed to provide such a reveal r 140 . Such a reveal is typically from 0% up to about 50% of the thickness t v of the vertical member. Such a reveal can be used for, among other things, a location for chinking or the like and/or running wiring, plumbing, and/or other utilities or the like as described below. In one example, a reveal up to ¾ inch (about ¼ inch being preferred) is provided for chinking or the like. The term “reveal” as used herein typically refers to a side of an opening between an outer surface and an inner surface. An example of such a side of an opening is provided by r 140 with respect to the outer surface of member 120 (opposite F i ) and to the inner surface F o of member 130 .
[0055] In another example of a fabricated timber 100 , a vertical member (e.g. 120 ) is positioned atop a horizontal member (e.g., 130 ) such that no reveal is provided, but such that the outer face of the vertical member is substantially flush with the outer side of the horizontal member instead. Such a “no reveal” configuration may provide for stacked timbers that have an appearance of a square log with a height that is the combined height of the stacked timbers where the horizontal interfaces between the stacked logs are dressed so as to be substantially non-visible. Other “no reveal” configurations are also acceptable, as described below.
[0056] The term “dressed” (“dressing”, “dress”, and the like) as used herein typically indicates treating the outside faces of individual or stacked fabricated timbers and/or interfaces of stacked fabricated timbers to have a desired appearance. For example, it may be desirable for the outside faces of fabricated timbers to have the appearance of a square log, a peeled log, and/or a rough-hewn log, or the like. In one example, the outside faces and/or interfaces of such timbers may be distressed using a chainsaw or the like to produce an appearance and texture of a rough-hewn log. Interfaces may be filled with wood filler or the like to hide them before or after distressing. Such dressing or distressing may be performed prior to timbers being stacked, or after stacking, or both. The term “desired” as used herein typically refers to some quality or characteristic or the like that is expected as a result of some action, design, planning, or the like.
[0057] Other aspects of the term “dressed” as used herein may include staining, tinting, painting, or otherwise coloring, finishing, and/or otherwise treating the faces, visible portions, and/or interfaces of fabricated timbers. Other examples may include sealing and/or waterproofing or the like. Another example may include chinking, such as with conventional chinking, cement, sand mortar, grout, flexible vinyl chinking, or the like. Conventionally, chinking is used to seal gaps between logs. In the case of fabricated timbers, chinking is primarily used for aesthetic reasons and to obtain a conventional chinked appearance or the like.
[0058] Various attributes that a fabricated timber 100 configured for building construction should possess include the capability of sustaining various loads including at least dead loads, live loads, and environmental loads. The noun “building” as used herein typically refers to a structure (generally enclosed by walls and a roof) constructed to provide support and shelter for an intended occupancy. The term “occupancy” as used herein typically refers to the purpose for which a building or other structure, or portion thereof, is used or intended to be used. The term “load” as used herein typically refers to forces or other actions upon a building that result from the weight of building materials and the like, building occupants and/or their possessions, objects supported by the building, environmental effects, differential movement, restrained dimensional changes, and the like. The term “dead loads” as used herein typically refers to substantially permanent loads such as the weight of materials of construction incorporated into a building or structure including but not limited to walls, floors, roofs, ceilings, stairways, built-in partitions, finishes, and all other similarly incorporated construction materials, and all equipment and the like affixed to the building or structure, but not including live loads or environmental loads. In one example, a fabricated timber may be configured to sustain a desired dead load of at least fifteen pounds per square foot. The term “live loads” as used herein typically refers to loads produced by occupancy of a building or structure that do not include dead loads or environmental loads. In one example, a fabricated timber may be configured to support a desired live load of at least thirty pounds per square foot. The term “environmental loads” as used herein typically refers to loads that act on a building or structure as a result of weather, topography, or other natural phenomena including but not limited to wind, snow, rain, ice, seismic activity, temperature variations leading to thermal expansion or the like, ponding, dust, fluids, floods, and lateral pressures from soil, ground water, bulk materials against the building, and the like, but not including dead loads or live loads. In one example, a fabricated timber may be configured to support a desired environmental load of at least ten pounds per square foot. In another example, a fabricated timber may be configured to support at least the desired dead load, live load, and environmental load combined. The term “support” as used herein with respect to a fabricated timber typically indicates a capability to bear desired loads plus a safety factor without exceeding a yield strength of the fabricated timber or, in other words, while maintaining its elasticity.
[0059] FIG. 2 a is a diagram showing a top view of an example fabricated timber 100 . This top view shows portions of example horizontal member 130 and example vertical members 110 and 120 , as also shown in FIGS. 1 a and 1 b . Also shown in FIG. 2 a are holes (e.g., 220 ) of sufficient diameter to allow tie-down fasteners to pass through horizontal member 130 via the holes, as well as blocking (e.g., 224 ) optionally disposed on one or both sides of each hole. In one example, holes (e.g., 220 ) in the horizontal member are located approximately every m feet on center. The term “every m feet on center” as used herein refers to a hole at least every m feet along the length l of the horizontal member, each such hole approximately centered within the width w of the horizontal member (e.g., 130 ). In another example, holes (e.g., 220 ) may be provided at other increments (e.g., every b units) along the length l of the horizontal member. In other examples, a fabricated timber 100 may be fabricated to include the holes (e.g., 220 ) and optional blocking (e.g., 224 ) as a single member. Note that any blocking (e.g., 224 ) may comprise holes and/or notches (e.g., 225 ) to facilitate utility runs such as wiring, plumbing, etc. Any one block may comprise from one to four corner notches (only one 225 shown in FIG. 2 b ) and/or any number of holes. Generally all blocking in a fabricated timber would comprise the same hole/notch number and pattern. The size of the holes/notches (e.g., 225 ) is typically sufficient for desired runs of wiring, plumbing, and other utilities and the like. Such blocking holes/notches (e.g., 225 ) may alternatively be referred to as “blocking utility ports”.
[0060] FIG. 2 b is a diagram showing an end view of the example fabricated timber 100 . This end view shows portions of example horizontal member 130 and example vertical members 110 and 120 , as also shown in FIGS. 1 a and 1 b . Also shown in FIG. 2 b is an end view of example blocking 224 . The composition of the blocking (e.g., 224 ) is typically the same as that of the fabricated timber's members (e.g., 110 , 120 , and 130 ). Further, should the material from which members 110 , 120 , 130 , and 224 are fabricated include a grain (as with e.g., wood, fiber-cement, etc.), the grain of each member, including blocking members (e.g., 224 ), should be oriented in substantially the same plane. Such grain alignment may result in shrinkage over time that is relatively consistent between each of the members. In one example, blocking (e.g., 224 ) is attached to vertical member (e.g., 110 and 120 ) with fasteners (e.g., 226 ) as illustrated in FIG. 2 b . In a particular example, blocking is fastened by installing two nails on each side (e.g., 110 and 120 ), as illustrated. Alternatively or additionally, the fasteners (e.g., 226 ) may be installed on the bottom (e.g., 130 ) and/or through the bottom of a next timber (e.g., FIG. 3 , 330 ), leaving the outer faces of the vertical members free from any appearance of fasteners. In another example, other types or sizes of fasteners may be installed to fasten blocking. Note that the height h of the blocking is substantially the same as the height h of vertical members 110 and 120 . Preferably, the blocking height is not greater than, but may be the same as or somewhat less than the height of the vertical members.
[0061] FIG. 3 is a diagram showing an example wall 300 constructed from a plurality of example fabricated timbers (e.g., 100 i , 100 , and 100 t ). In this example, bottom fabricated timber 100 i is attached atop foundation 310 . Alternatively, the bottom fabricated timber 100 i may be positioned atop any other type of foundation suitable for a building or structure. The term “foundation” as used herein typically refers to the lowest load-bearing portion of a building which may comprise any suitable design and material. In this example, tie-down fasteners (e.g., 312 ) may be embedded in or attached to the foundation using conventional techniques. The tie-down fasteners may be comprised of multiple components (e.g., 312 , 320 , and 322 ) and may continue upward via holes in the horizontal member (e.g., 130 ) of each fabricated timber (e.g., 100 i , 100 , and 100 t , as well as all other fabricated timbers). The term “tie-down fastener” as used herein typically refers to a fastening device or mechanism configured to secure some object(s) (e.g., a fabricated timber(s)) against a base of some kind (e.g., a foundation).
[0062] In one example, bottom fabricated timber 100 i may include an optional additional member (e.g., 316 ) that may be fastened to the top of its horizontal member inside the timber via fasteners (e.g., 314 ) and further attached to the foundation via a nut and washer or the like (e.g, 318 ), thus locking down the bottom fabricated timber 100 i to the foundation.
[0063] Example wall 300 extends upward to the desired height by stacking and attaching fabricated timbers one atop another starting with a bottom fabricated timber (e.g., 100 i ) up through the top fabricated timber (e.g., 100 t ). The fabricated timbers are typically stacked so as to be level horizontally and to be substantially plumb. Such stacking can typically be performed by two or three people (workers) without the use of a crane or other heavy equipment or the like. The holes in the horizontal members may be sufficiently aligned vertically so as to allow tie-down fasteners (e.g., 312 & 320 ) to pass through each stacked fabricated timber while remaining substantially plumb vertically. In one example, the holes are drilled or otherwise formed by the workers as the timbers are stacked. One method of finding the correct location for each hole is to place the next timber in the desired horizontal position above the lower timber and atop the applicable and substantially plumb tie-down fasteners, beat the horizontal member of the next timber against the tops of the tie-down fasteners so as to form discernible marks on its bottom at the locations where the tie-down fasteners touch the horizontal member, and then drill or otherwise form the holes according to the marks. This method typically allows for the holes to be formed by the workers at the required locations along the horizontal member of the next timber at the job site without complex design or measurements or the like.
[0064] Regarding the tie-down fasteners, these fasteners may be attached to or embedded in foundation 310 at their lower ends, that extend through the courses of stacked fabricated timbers forming a wall, and that are fastened to the top of the wall thus maintaining the wall in a high degree of force over time against the foundation (e.g., 310 ). Such tie-down fasteners may be configured to maintain the high degree of force on the wall, even in the event of shrinkage of the wall's fabricated timbers and in the event that various forces are applied to the wall, including environmental forces such as wind, earthquake, shifting, flooding, and the like.
[0065] In one example, each tie-down fastener may be a threaded rod, or a plurality of threaded rods (e.g., 320 ) coupled together by coupler nuts (e.g., 322 ). A bottom rod, also known as an anchor bolt, (e.g., 312 ) may be embedded in or otherwise attached to the building's foundation (e.g., 310 ) via conventional means. The bottom rod may be sufficiently long to pass through the first course of fabricated timbers (e.g., 100 i ) and may be coupled via a coupling nut (e.g., 322 ) or the like to a second rod (e.g., 320 ) that is sufficiently long to pass through at least a second course of fabricated timbers, etc., until a final rod or top portion of a single rod passes into and/or through a top fabricated timber (e.g., 100 t ). In one example, a tie-down fastener and related components may terminate against the horizontal member of the top fabricated timber. In another example, wall cap members 332 and 334 may cap the final course of fabricated timbers and allow for the tie-down fastener(s) to hold the stacked courses of fabricated timbers against the building foundation (e.g., 310 ). Member 332 may be optional. Member 334 may be the same width as a horizontal member (e.g., 130 ) or extend up to the entire width of a fabricated timber (e.g., 100 t ). The desired holding force may be achieved via a tensioner mechanism (e.g., 333 ) such as a spring or the like positioned atop a washer or plate (e.g., 331 ) locked in position via the rod (e.g., 320 ) by a nut (e.g., 336 ) and washer (e.g., 335 ) or other suitable locking device(s). Any other suitable tensioner mechanism may alternatively/additionally be used to provide the desired force on the wall 300 . In one example (not illustrated), the tensioner mechanism may be installed on top of wall top cap (e.g., 332 and 334 ). In another example, the tensioner mechanism may be installed inside the top fabricated timber 100 t against its horizontal member as illustrated in FIG. 3 . In one example of a wall constructed using fabricated timbers, the tie-down fasteners comprise threaded metal rods (e.g., 320 ) ⅝ inches in diameter joined by coupler nuts (e.g., 322 ) as needed, the bottom rods or anchor bolts (e.g., 312 ) embedded at least 6 inches in a conventional concrete foundation (e.g., 310 ), the tie-down fasteners spaced at least every 4 feet along the horizontal length of the wall (e.g., 300 ), with the top ends attached via tensioner mechanisms (e.g., 333 ) and associated components (e.g., 331 , 335 , and 336 ), and where each combination of tie-down fastener, tensioner mechanism, and associated components (e.g., 331 , 335 , and 336 ) has a tension capacity of at least 2,500 lbs. The term “tension capacity” as used herein is related to a material's or object(s)'s “tensile strength” and indicates a rated usage value below such a tensile strength. The term “associated components” as used herein typically refers to various pieces of hardware or the like required to complete, secure, and/or retain a tie-down fastener and/or tensioner mechanism, pieces of hardware such as washers, plates, nuts, pins, and the like.
[0066] Each course of fabricated timbers of a wall is typically attached to the previous course. FIG. 3 shows an example of how one course can be attached to the previous course. In this example, fasteners (e.g., 328 and 330 ) are installed to attach a next fabricated timber that is being stacked atop a previously stacked fabricated timber. Fasteners (e.g., 328 ) are installed so as to attach the horizontal member of the next fabricated timber to the vertical members (e.g., 110 and 120 ) of the previous fabricated timber (e.g., 110 ). Further, additional fasteners (e.g., 330 ) may be installed so as to attach the horizontal member of the next fabricated timber to some or all of the blocking (e.g., 224 ) of the previous fabricated timber (e.g., 110 ).
[0067] Prior to attaching a next fabricated timber to the previous fabricated timber, gaps and the like between the two may be substantially removed. In one example, this is done by compressing the next fabricated timber against the previous fabricated timber sufficient to remove such gaps. Such may be accomplished using existing tie-down fasteners to force the next fabricated timber toward the foundation until gaps and the like between the next fabricated timber and the previous fabricated timber are substantially eliminated. Given a threaded rod tie-down fastener, a plate or the like may be slid down the rod against the top of the next fabricated timber, and a nut tightened against the plate to remove any gaps. Then, while under compression with gaps substantially removed, the next fabricated timber may be attached to the previous fabricated timber.
[0068] As one fabricated timber is stacked atop another, one or more beads of caulking and/or glue or the like may be applied. In one example, a bead of caulking may be applied along the length of a top of a fabricated timber's vertical members (e.g., 110 and 120 ) prior to stacking another fabricated timber on top of it. Such a bead may be applied along the inside and/or outside edge(s) of the vertical members, or along any other portion of the vertical members. One such bead may be formed from a caulking or the like that is configured to remain flexible over time, though cycles of hot and cold seasons, and to seal out moisture, bugs, air, and/or other substances and/or objects, and be further configured to maintain such a seal given settling, movement, shrinkage, or the like of the fabricated timbers. Another such bead may be similarly applied that is formed of glue or construction adhesive or the like.
[0069] A wall constructed of fabricated timbers that supports angled trusses may also include weight distribution members that typically approximate the shape of a right triangle, as illustrated in FIG. 3 by element 340 . In one example, one such weight distribution member (e.g., 340 ) is installed atop the wall (e.g., 300 ) under each truss (e.g., 338 ). Each such weight distribution member is typically disposed and configured to evenly distribute the various loads imposed by the truss across the top surface of the top course of fabricated timbers (e.g., 100 t ). The width of such a weight distribution member is typically about the same as the width of the wall top cap or the like that it is disposed upon. The height and hypotenuse of the weight distribution member are typically configured to support the truss by contact along the length of the hypotenuse. Such a weight distribution member may be fabricated any of the materials suitable for members of a fabricated timber.
[0070] FIG. 4 is a diagram showing an example method 400 for constructing a fabricated timber. Such timbers may be partially or completely assembled as pre-manufactured timbers off-site at a factory or the like, or they may be partially or entirely assembled on-site. In both cases, the basic process of construction is typically the same.
[0071] Block 402 typically indicates determining a total desired load plus a safety factor that the fabricated timber should support without exceeding its yield strength. The total desired load may be a minimum, and is typically comprised of a determined desired minimum dead load (block 410 ) plus a determined desired minimum live load (block 420 ) plus a determined desired minimum environmental load (block 430 ). Each of these determined loads may be based at least on the overall design, occupancy, and physical environment of the building. Alternatively, desired average, maximum, or other loads may be used instead of desired minimum loads.
[0072] Block 440 typically indicates determining a composition of each of the various members of the fabricated timber. Such determining may be based at least on the determined desired loads (e.g., block 402 ) and aspects of the design, occupancy, and physical environment of the building comprising the fabricated timber. Such determining may also take into account a desired outside dressing and/or desired inside dressing of the fabricated timber. Note that the various members of a fabricated timber need not be of the same composition. Nor need one fabricated timber (or various members thereof) used in a building be of the same composition as another fabricated timber (or various members thereof) used in the building.
[0073] Block 440 also typically indicates determining a thickness of the various members of the fabricated timber, such as members 110 , 120 , 130 , and 224 . Such determining may be based at least on the determined desired loads (e.g., block 402 ) and aspects of the design, occupancy, and physical environment of the building comprising the fabricated timber. Such determining may also take into account a desired outside dressing and/or desired inside dressing of the fabricated timber. Note that the various members of a fabricated timber need not be of the same thickness. Nor need one fabricated timber (or various members thereof) used in a building be of the same thickness as another fabricated timber (or various members thereof) used in the building.
[0074] The end result of the determinings indicated by block 440 is generally that the compositions and thicknesses of the various members of the fabricated timber have been determined. Another aspect (not explicitly indicated in FIG. 4 ) is determining the length of the fabricated timber or each of the fabricated timbers used in a building or wall or the like. Generally the length of each fabricated timber is based upon it position in a wall of a building or the like, the position of windows, doors, and other opening, the length of the wall, etc. A typical fabricated timber may generally be between approximately one and thirty feet in length. Should a wall require greater lengths, two or more such fabricated timbers may be disposed end-to-end to obtain the desired overall length. Yet another aspect (not explicitly indicated in FIG. 4 ) is determining the width of the horizontal member and the height of the vertical members of the fabricated timber or of each of the fabricated timbers used in a building or wall or the like. The width may be determined based on a desired thickness of a wall or portion thereof. The desired thickness may be based on a desired amount of insulating value, a desired appearance, or other factors that may impact the width of a wall or portion thereof. The desired height may be determined based on a desired timber height, desired appearance, desired locations of windows and/or other openings, desired wall heights, roof heights, and floor heights (such as in multi-level structures), and the like.
[0075] Block 442 typically indicates various aspects of constructing a fabricated timber. Block 450 typically indicates disposing a first vertical member atop a horizontal member. In one example, the first vertical member 110 is typically disposed length-wise atop the left side L (or the right side R) of horizontal member 130 , as illustrated in FIG. 1 b . The first vertical member may be disposed to provide a reveal r 140 , as illustrated in FIG. 1 b . The first vertical member 110 may be fastened to the horizontal member 130 using fasteners installed every n inches on center or the like, and/or the horizontal member and the first vertical member may be fabricated as a single piece. The disposing of the first vertical member atop the horizontal member may take place at a job site as part of the construction of a wall of a building, or as part of a process of construction a plurality of fabricated timbers such as for later use in constructing walls or the like.
[0076] Block 460 typically indicates disposing a second vertical member atop a horizontal member. In one example, the second vertical member 110 is typically disposed length-wise atop the right side R (or the left side L, whichever side the first vertical member is not disposed on), of horizontal member 130 , as illustrated in FIG. 1 b . The second vertical member may be disposed to provide a reveal r 140 , as illustrated in FIG. 1 b . The second vertical member 110 may be fastened to the horizontal member 130 using fasteners installed every n inches on center or the like, and/or the horizontal member and the second vertical member may be fabricated as a single piece. The disposing of the second vertical member atop the horizontal member may take place at a job site as part of construction of a wall of a building or the like, or as part of a process of construction a plurality of fabricated timbers for later use at another site in constructing walls or the like.
[0077] Block 470 typically indicates forming one or more holes in a horizontal member of a fabricated timber. In one example, each hole is formed so as to enable a tie-down fastener to pass through the fabricated timber via the hole. As fabricated timbers are stacked to form a wall, holes formed in each timber are typically aligned with holes formed in any timbers above and below such that a tie-down fastener can to pass through each set of aligned holes in a substantially vertical orientation, as partially illustrated in FIG. 3 . Such holes may be formed off-site during timber fabrication in advance of wall construction, or as part of wall construction at a job site (the location of building construction). Holes are typically formed to allow for tie-down fasteners to be installed at approximately two foot or greater intervals along the length of a wall constructed of fabricated timbers. In one example, holes are formed to allow for a tie-down fastener to be installed at approximately four foot intervals along the length of a wall.
[0078] Block 480 typically indicates installing a fabricated timber's blocking. One example of such blocking is illustrated in FIG. 2 a wherein a block is optionally installed on one or both sides of a formed hole. In one example, a block is installed about two to six inches on one or both sides of a formed hole's center. Such optional blocking is typically installed in each timber such that, when stacked, the blocking of the stacked timbers is substantially aligned vertically. That is, the optional hole blocking of one timber tends to be vertically aligned with that of any timbers above and/or below it. In another example, blocking may additionally or alternatively be installed at intervals unrelated to the location of formed holes. Such blocking of stacked timbers may be installed so as to be substantially aligned vertically. As with forming holes, blocking may be installed off-site during timber fabrication in advance of wall construction, or as part of wall construction at a job site.
[0079] FIG. 5 is a diagram showing an example method 500 for constructing a wall from fabricated timbers. Block 510 typically indicates attaching a timber used in constructing the wall. In one example, the first or bottom fabricated timber of a wall is typically attached to a foundation as described in connection with at least FIG. 3 , elements 100 i and 316 . In another example, a fabricated timber that is stacked upon another fabricated timber is attached as described in connection with at least FIG. 3 , element 328 . Further, holes are typically formed in fabricated timbers so as to enable tie-down fasteners to pass through the fabricated timber via the holes.
[0080] Further, one or more beads of caulking or glue or the like may be applied as a part of the attaching. In one example, a bead of caulking may be applied along the length of a top of a fabricated timber's vertical members (e.g., 110 and 120 ) prior to stacking another fabricated timber on top of it. Such a bead may be applied along the inside and/or outside edge(s) of the vertical members, or along any other portion of the vertical members. One such bead may be formed from a caulking or the like that is designed to remain flexible over time, cycles of hot and cold, and to seal out moisture, bugs, air, and or other substances and/or objects, and be further designed to maintain a seal given settling, movement, and/or shrinkage of the fabricated timbers. Another such bead may be formed from glue or construction adhesive or the like.
[0081] Block 520 typically indicates optionally extending a tie-down fastener(s) to pass through a next fabricated timber used to construct the wall. In one example, tie-down fasteners may be extended as described in connection with FIG. 3 , elements 320 and 322 . In another example, a tie-down fastener(s) may not require extending, such as in the case of using full wall height tie-down fasteners.
[0082] Block 530 typically indicates optionally installing utilities such as electrical wires, gas and/or water lines, ducting, and the like. In one example, electrical wires, water lines, gas lines, ducting, etc., may be run horizontally through the channel ( FIG. 1 a , 180 ) formed by a fabricated timber. Such may require forming holes/notches (e.g., 225 ) in blocking of the fabricated timber(s) to allow the utilities to pass through. In another example, electrical wires, water lines, gas lines, ducting, etc., may also be run vertically from one course of fabricated timbers to another. Such may require forming hole(s) in a horizontal member(s) of the fabricated timber(s) to allow the utilities to pass through. Further, holes may be formed in vertical member(s) of the fabricated timber(s) to allow the utilities to be accesses from the outside surface(s) of the fabricated timber(s). Such holes may be formed to allow for outlets, valves, vents, receptacles, etc.
[0083] Block 540 typically indicates optionally installing insulation. In one example, insulation is installed in the channel ( FIG. 1 a , 180 ) formed by a fabricated timber. Any form of insulation may be installed, or no insulation at all depending on the application of the wall and/or preferences of the builder. Generally, a sufficient quantity of a particular type of insulation is used to provide an insulation R-value (conventional measure of thermal resistance) sufficient for the purpose and location of the wall.
[0084] Once a particular course of fabricated timbers have been stacked and attached, any desired utilities have been run, and any tie-down fasteners have been installed and/or extended, then that course of fabricated timbers is typically complete and a next course may be attached. Block 550 typically indicates determining if there is at least one additional course to be added to the wall being constructed. If so, method 500 continues again at block 510 . Otherwise method 500 continues at block 560 .
[0085] Block 560 typically indicates installing a wall cap at the top of a fabricated timber-based wall. In one example, a wall cap may be fabricated and installed as described in connection with FIG. 3 , elements 332 , 334 , and 336 . Installing wall caps may include forming holes so as to enable tie-down fasteners to pass through the wall caps via the holes. Further, installing wall caps may include applying a bead(s) of caulking and/or glue or the like along the length of a top of the top fabricated timber's vertical members (e.g., 110 and 120 ) prior to installing a wall cap on top of it. Such a bead may be applied along the inside and/or outside edge(s) of the vertical members, or along any other portion of the vertical members. One such bead may be formed from a caulking or the like that is designed to remain flexible over time, through cycles of hot and cold, and to seal out moisture, bugs, air, and/or other substances and/or objects, and be further designed to maintain a seal given settling, movement, and/or shrinkage of the fabricated timbers and/or wall cap. Another such bead may be similarly applied that is formed of glue or construction adhesive or the like.
[0086] Block 570 typically indicates installing tensioner mechanisms to any tie-down fasteners. In one example, such may be installed inside a fabricated timber. In another example, such may be installed on wall caps at the top of a wall.
[0087] Block 580 typically indicates optionally installing chinking in any reveals of the constructed wall, such as reveal 140 of FIG. 1 a that may be provided by fabricated timbers of the wall. Such chinking may comprise material that is intended to be functional and/or decorative in nature. Conventional chinking materials may be used, and/or other non-conventional chinking materials. For example, mortar, stucco, caulk, grout, and/or the like may be used for chinking. Any such materials may be applied using conventional means. In one example, wire mesh may be installed in the reveal area and the chinking material applied over the installed wire mesh. In another example, chinking material may be applied directly to the reveal areas of the stacked fabricated timbers. In another example, electrical wiring may be run along the reveal areas, nail guards installed to protect the electrical wiring, and chinking installed over the nail guard with or without wire mesh.
[0088] FIG. 6 a is a diagram showing an end view of an example alternate fabricated timber 600 with a 3-dimensional view the same example alternate fabricated timber 600 shown in FIG. 6 b . Such a timber according to this example is typically fabricated in a similar manner to that of example fabricated timber of FIG. 1 a and 1 b , with the additional of top horizontal member 190 that may have similar properties, attributes, uses, and characteristics to those of bottom horizontal timber 130 . Further, such a timber according to this example can be used in conjunction with fabricated timbers (e.g., 100 ). In one example, alternate fabricated timbers (e.g., 600 ) may be used for the outside walls of a building while fabricated timbers (e.g., 100 ) may be used for inside walls of the same building. The two types of timbers (as well as other types) may even both be used in the same wall. Other combinations of the two timbers are also acceptable. Regarding construction of an alternate fabricated timber (e.g., 600 ), top horizontal member 190 may be attached to the tops of vertical members 110 and 120 in a manner similar to that of bottom horizontal member 130 .
[0089] Alternate fabricated timbers (e.g., 600 ) may be fabricated to be insulated and fully enclosed either at a fabrication site or on a job site. Holes for tie-down fasteners may also be formed either at the fabrication site or on the job site. Blocking may be used to enclose the ends of an alternate fabricated timber, and may be built in at approximately two foot or greater intervals along the length of the timber. Blocking in both fabricated timbers and alternate fabricated timbers may also include holes configured to provide runs for utilities along the length of the inside of alternate fabricated timbers. An alternate fabricated timber may include conduit(s) installed in one or more sets of utility holes in the blocking, the conduit(s) typically extending from one end of the timber to the other. Such conduits may be used to run utilities through alternate fabricated timbers. Blocking in alternate fabricated timbers need not be included on either side of holes formed for tie-down fasteners. Further, horizontal members 130 and/or 190 may include channels or grooves along the length of their outer faces (not shown), the channels configured to provide a run for electrical wiring or the like.
[0090] FIG. 6 c is a diagram showing an example of incorporating housewrap in a fabricated timber such as that shown in FIGS. 6 a and 6 b (that show additional detail not shown in FIG. 6 c ). In FIG. 6 c , horizontal members 130 and 190 are shown separated from vertical members 110 and 120 to more clearly illustrate how the housewrap is incorporated into the timber; but this separation is for illustrative purposes only. The term “housewrap” as used herein refers to materials that function as weather-resistant barriers for preventing rain, snow, ice, and the like from getting inside a timber (e.g., 600 of FIGS. 6 a and 6 b ) or a wall assembly constructed of such timbers (e.g., 700 of FIG. 7 ) while allowing water vapor to pass to the exterior. Some examples of housewraps include asphalt-impregnated materials such as paper or fiberglass or the like, and synthetic films and the like such as Tyvek. Fabricated timbers with house wrap incorporated can achieve superior weather resistance to conventional logs because as the latter age and crack moisture can get into and even through the wood. But fabricated timbers with house wrap properly incorporated can reduce or prevent such problems even if the outer layer of wood cracks or is otherwise damaged.
[0091] In one example, as shown in FIG. 6 c , house wrap 610 is disposed over the entire inner face F i (i.e., over the entire length l and height h) of the outer vertical member 110 of the fabricated timber and folds over the top portion 110 and the bottom portion 110 b of member 110 , as illustrated, resulting in an upper flap of 610 and a lower flap of 610 . The outer vertical member is typically the member that is exposed to the weather on the outside of a structure. But housewrap may alternatively or additionally be similarly incorporated in fabricated timbers on inside members (e.g., 120 of FIGS. 3 and 7 ). The housewrap may be attached to inner face F i (and/or to the top and bottom faces) of member 110 using any desired means, including adhesive and/or staples 620 . These flaps are later used to seal the adjoining reveals of stacked fabricated timbers, as discussed later in connection with FIG. 6 d . In addition to incorporating housewrap into fabricated timbers, exposed surfaces of such fabricated timbers may be coated, sealed, infused, dressed, or finished with a water-resistant or weather-resistant material, such as chemical treatments, sealants, coatings, films, or the like.
[0092] The term “backed and flapped housewrap” as used in the claims is defined herein to mean: housewrap that is disposed over an inner face of a vertical member of a fabricated timber and that folds over the top and bottom portions of the vertical member resulting in an upper and lower flap of the housewrap, as described in FIG. 6 c and the corresponding written description.
[0093] FIG. 7 is a diagram showing an example wall 700 constructed from a plurality of example alternate fabricated timbers (e.g., 600 ). Like reference numbers refer to like elements within FIG. 7 and between figures. Wall 700 is constructed in much the same way as wall 300 , with some variations to account for the use of alternate fabricated timbers (e.g., 600 ) versus fabricated timbers (e.g., 100 ). One variation may be how one course of alternate fabricated timbers is attached to another course. In one example, strapping 720 is run along adjoining reveals of two stacked courses of alternate fabricated timbers and attached with fasteners 710 at regular intervals, such as approximately every twenty-four inches. Strapping 720 may be formed of solid or perforated metal or the like configured for using nails or the like as fasteners 710 . Alternatively, strapping 720 may be formed of various sized plates or the like, or of construction tape or the like with adhesive or the like performing the function of fasteners 710 . In another example, individual brackets or the like may be used at intervals along the length of courses. Other mechanisms may alternatively and/or additionally be utilized to lock one course to another course when using alternate fabricated timbers.
[0094] In one example, the tensioner mechanism and related components may be installed on top of the wall top cap. In another example, the tensioner mechanism may be installed inside the top fabricated timber 600 t against its bottom horizontal member.
[0095] Another variation may be how blocking is locked into place in an alternate fabricated timber. In one example, blocking in alternate fabricated timbers may be installed at four-foot or less intervals. Fasteners may be installed via the top and bottom horizontal members of an alternate fabricated timber as opposed to via the vertical members. This approach has the advantage of fasteners not being visible on the outside vertical faces of an alternate fabricated timber.
[0096] Another variation may be how a tensioner mechanism and related components are configured. In one example, a plate 733 or the like may be used in conjunction with a tensioner mechanism and a washer 335 and nut 336 . Plate 335 is typically configured to distribute forces from any tensioner mechanism(s) (e.g., 734 ) down the vertical members of alternate fabricated timbers to the foundation. Plate 335 may be made of metal or any other material configured to provide the required force distribution. In one example, plate 335 is a steel plate between ⅛″ and ½″ in thickness that extends substantially across the width of the mating surface of the bottom horizontal member. In another example, plate 335 may alternatively be formed of angle iron or the like, or I-beam or channel or the like.
[0097] Other variations may also include how a bottom course of alternate fabricated timbers is attached to a foundation, how a tie-down fastener is attached to an alternate fabricated timber, etc. Further, alternate fabricated timbers (e.g., 600 ) may be used in combination with fabricated timbers (e.g., FIG. 3 , 100 ). In one example, regular fabricated timbers (e.g., FIG. 3 , 100 ) may be used against a foundation as described in connection with FIG. 3 , 100 i , and a top horizontal member may optionally be added. In another example, regular fabricated timbers (e.g., FIG. 3 , 100 ) may be used for a top course along with regular wall cap members (e.g., FIG. 3 , 332 / 334 ). In another example, a member (e.g., 714 ) similar to a horizontal member of a fabricated timber may be disposed atop the foundation (e.g., 310 ) and a first alternate fabricated timber may be stacked and attached atop the member (e.g., 714 ). In one example, such a member (e.g., 714 ) may be made of pressure-treated 2× lumber or the like. Such a configuration may provide a reveal at a bottom course that is consistent in depth and height with that resulting from two alternate fabricated timbers being stacked one atop the other.
[0098] Weatherizing a wall constructed from a plurality of example alternate fabricated timbers (e.g., 600 ) and/or other styles of fabricated timbers (e.g., 100 ) may be desirable. In one example, such weatherizing can be accomplished by stacking fabricated timbers that incorporate housewrap, such as described in connection with FIG. 6 c . An example of sealing the adjoining reveals of two stacked fabricated timbers is shown in FIG. 6 d . The term “weatherize” in its various forms as used herein means to better protect fabricated timbers and/or walls constructed of fabricated timbers from the elements than they would be without being weatherized, where such elements may include weather conditions such as wind, rain, snow, ice, hail, heat, cold, any other weather condition, and any combination thereof.
[0099] First, as illustrated, the upper flap of housewrap 610 l of lower fabricated timber 600 l is folded up to cover the outer faces F ol and F ou of the adjoining reveals of the corresponding upper and lower fabricated timbers 600 u and 600 l respectively. The folded upper flap of housewrap 610 l typically also covers any strapping or the like (e.g., 720 of FIG. 7 ) that may be used to join upper and lower fabricated timbers 600 u and 600 l respectively. The folded upper flap of housewrap 610 l may then be trimmed such that it covers the entire faces F ol and F ou of the adjoining reveals for the entire length l of fabricated timbers 600 u and 600 l . The folded upper flap of housewrap 610 l may also be attached along the length l of faces F ol and F ou of the adjoining reveals using any desired means, including adhesive and/or staples 620 . In one example, trimming may be performed before the attaching. In another example, the attaching may be performed before the trimming.
[0100] Second, as illustrated, the lower flap of housewrap 610 u of lower fabricated timber 600 u is folded down to cover the folded upper flaps covering outer faces F ol and F ou of the adjoining reveals of the corresponding upper and lower fabricated timbers 600 u and 600 l respectively. The folded lower flap of housewrap 610 u may then be trimmed such that it covers the entire faces F ol and F ou of the adjoining reveals for the entire length l of fabricated timbers 600 u and 600 l . The folded lower flap of housewrap 610 u may also be attached along the length l of faces F ol and F ou of the adjoining reveals using any desired means, including adhesive and/or staples 620 . In one example, trimming make be performed before the attaching. In another example, the attaching may be performed before the trimming.
[0101] House wrap may similarly be incorporated in walls constructed of other styles of fabricated timbers, including those illustrated in FIGS. 1 a , 1 b , 3 , 8 , 9 , 10 a , and 10 b , or of any combination of types. The phrase “folded and sealed” with respect to backed and flapped housewrap as used in the claims is defined herein to mean: the backed and flapped housewraps of two stacked fabricated timbers of any type that are folded over their adjoining reveals as described in FIG. 6 d and the corresponding written description.
[0102] It may be desirable to chink any reveals in walls that include any fabricated timbers that incorporate backed and flapped housewrap that have been folded and sealed. But, depending at least on the type of housewrap incorporated, various chinking materials may not adhere to the housewrap that covers the reveals of the housewrapped fabricated timbers. To solve this problem, in one example the housewrapped reveals are first coated with an adhesive that is capable of bonding to the housewrap and to the chinking material that will be used. Then, while the adhesive is at least somewhat wet or uncured, chinking material is applied on top of the adhesive. After the chinking is applied, the adhesive and the chinking are allowed to dry or cure.
[0103] Tall solid wood timbers tend to be very expensive because old growth trees of sufficient size are scarce. Therefore, tall timbers tend to be desirable. FIG. 8 a is a diagram showing an example of a tall fabricated timber that has the appearance of an expensive tall solid wood timber. Such a tall fabricated timber may be constructed for use as a fabricated timber (e.g., 100 ), as an alternate fabricated timber (e.g., 600 ), or as any other style of fabricated timber (e.g., FIGS. 9 and 10 ). FIG. 8 a illustrates a tall fabricated timber comprising three sections. In one example, section 1 may be a fabricated timber (e.g., 100 ). Sections 2 and 3 are tall fabricated timber sections. Section 2 is shown stacked upon and attached to section 1 (e.g., using fasteners 840 on both sides). Arrows 890 indicates stacking section 3 on top of section 2. In one example, as illustrated by section 3, a tall fabricated timber section comprises vertical members 810 and 820 that are typically formed of substantially the same material as vertical members 110 and 120 . The height of vertical members 810 and/or 820 need not be the same as that of 110 and 120 or of each other. In one example, the base member (e.g., 830 + 831 ) of each tall fabricated timber section is typically made of two pieces of 2× lumber attached together as illustrated. Alternatively, the base member may be made of a single piece of lumber or other material, as illustrated in FIG. 8 b . Typically, the base member extends along the length of the section but may alternatively made of various pieces with gaps between.
[0104] The sections (e.g., sections 1-3) may be stacked, compressed, and attached as described elsewhere herein, resulting in a tall fabricated timber. Such a tall fabricated timber may be up to the height of a wall it is used to form. Each set of vertical members that make up a particular side of a tall fabricated timber, such as individual vertical member 120 of section 1, and individual vertical members 820 of sections 2 and 3, are referred to herein as a “compound vertical member”—that is, a compound vertical member is composed of more than one individual vertical member, such as 3 individual vertical members in the non-limiting examples illustrated in FIGS. 8 a and 8 b . Tall fabricated timbers typically include such composite vertical members.
[0105] FIG. 8 b is a diagram showing an example of another tall fabricated timber. In this example, the base member (e.g., 1230 ) of each tall fabricated timber section is typically made of one piece of 2× lumber. In all other material aspects, the tall fabricated timber illustrated in FIG. 8 b may be substantially the same as the tall fabricated timber illustrated in FIG. 8 a.
[0106] FIG. 9 is a diagram showing an example of construction of a single-reveal fabricated timber (e.g., 900 i , 900 , and 900 t ) that has the appearance of an expensive solid tall wood timber on one side and a reveal on the other side. Either side may be used on the inside or outside of a building. Such a single-reveal fabricated timber may be constructed in much the same manner as a fabricated timber (e.g., 100 ) and/or an alternate fabricated timber (e.g., 600 ). Vertical member 920 varies from vertical member 120 in that its height is the same as that of the entire timber. Horizontal member 930 varies from horizontal member 130 in that its width is sufficient to provide a desired reveal on one side while the end of the other side abuts the inside bottom face of vertical member 920 such that the bottom face of horizontal member 930 is even with and parallel to the bottom end of vertical member 920 , as illustrated. Such single-reveal fabricated timbers may be stacked, compressed, and attached using fasteners (e.g., 840 ) as described elsewhere herein.
[0107] FIG. 10 is a diagram showing an example of construction of a single-reveal alternate fabricated timber (e.g., 1000 i , 1000 , and 1000 t ) that has the appearance of an expensive solid tall wood timber on one side and a reveal on the other side. Either side may be used on the inside or outside of a building. Such a single-reveal alternate fabricated timber may be constructed in much the same manner as a fabricated timber (e.g., 100 ) and/or an alternate fabricated timber (e.g., 600 ). Vertical member 920 varies from vertical member 120 in that its height is the same as that of the entire timber. Top and bottom horizontal members 930 vary from horizontal member 130 in that their width is sufficient to provide a desired reveal on one side while the end of the other side abuts the corresponding inside top or bottom face of vertical member 920 such that the corresponding top or bottom face of horizontal member 930 is even with and parallel to the corresponding top or bottom end of vertical member 920 , as illustrated. Such single-reveal alternate fabricated timbers may be stacked, compressed, and attached using fasteners (e.g., 710 , 720 , and 840 ) as described elsewhere herein.
[0108] FIG. 11 a is a diagram showing front and side views of an example of a fabricated timber end cap (e.g., 1100 ). Such end caps may be attached to exposed/open ends of wall timbers where the height and width of each end cap is typically substantially equal to the height and width of the timber end. Any suitable method of attachment may be used, including fasteners such as nails, glue, and/or any others indicated herein and/or the like. Each end cap may be beveled, as illustrated, or otherwise shaped as desired. Further, such end caps may be dressed, either prior to or after attachment, so as to match the appearance of the timbers to which they are attached and/or to create the appearance of being integral portions of such timbers.
[0109] FIG. 11 b is a diagram showing front and side views of an example of another fabricated timber end cap (e.g., 1101 ). The length l of this example end cap may be significantly longer than that of end cap 1100 ; it may be up to several feet or more in length so as to give the appearance of extending the fabricated timber to which it is mounted. The end cap may be shaped in any desirable fashion, such as with beveled edges at the end (as shown) or otherwise. The end cap typically has an outer height h o and width w o (not shown) that is substantially the same as the outer height and width of the fabricated timber being finished by the end cap. Further, end cap 1100 may be composed of any materials in any combination of which any fabricated timber may be composed.
[0110] End cap 1101 may include a mounting end (e.g., 1102 ) configured for being snuggly inserted into an open end of the fabricated timber being finished by the end cap. Glue and/or fasteners of any desired type may be used to retain the end cap in place. The mounting end is typically of an outside height h i and width w i (not shown) that is substantially the same as the inner height and width of the open end of the fabricated timber being finished by the end cap.
[0111] End cap 1101 may include a natural or artificial grain 1104 (e.g., a wood grain) that is oriented substantially consistent with any grain of the fabricated timber being finished by the end cap. In this manner, the end cap and the fabricated timber may provide the appearance of being a single piece. Further, any exposed joints between the fabricated timber and the end cap may be dressed as described in FIG. 12 and the corresponding written description. In all other material aspects, end cap 1101 may be the same as end cap 1100 .
[0112] FIG. 12 is a diagram showing an example method 1200 for dressing joints of a fabricated timber, including a tall fabricated timber, and joints of walls constructed of fabricated timbers. Method 1200 may also be applied to dress joints associated with end caps, such as those described in FIGS. 11 a and 11 b , or any other joints, seams, junctions, interfaces, cracks, gaps, fissures, flaws, or the like (all referred to herein by the term “joints”) in a fabricated timber or in various other surfaces. Method 1200 is particularly applicable to dressing joints in wood. Properly performed, performance of method 1200 can result in benefits including hiding such joints to give the appearance that the joints do not exist. In particular, given a tall fabricated timber with at least one compound vertical member, joints such as those between individual vertical members (e.g., 1290 of FIG. 8 b ) of a compound vertical member, or any other joints, such as any between an end cap and a fabricated timber of any style, can be dressed based on method 1200 to provide the benefits thereof. The term “joint surface” as used herein is defined to mean any surface of a fabricated timber, of a wall constructed of fabricated timbers, of any end cap, of any other surface such as a wood surface that includes a joint as defined above, and any combination thereof.
[0113] Method 1200 applies to any joint as defined above, and block 1210 typically indicates removing any dry adhesive protruding from a joint of a joint surface. In one example, the removing can be quickly accomplished using an angle grinder. Once any protruding glue has been removed, the method continues at block 1220 .
[0114] Block 1220 typically indicates applying fresh adhesive in the joint. In one example, a bead of adhesive is applied along the joint. Once the fresh adhesive has been applied, the method continues at block 1220 .
[0115] Block 1230 typically indicates applying sawdust to the freshly applied adhesive. In one example, the sawdust is of the same type of wood from which the joint surface is composed. The sawdust may be applied liberally. In one example, the freshly applied adhesive may be allowed to partially cure prior to applying the sawdust. Once the sawdust has been applied, the method continues at block 1240 .
[0116] Block 1240 typically indicates pressing the applied sawdust and the applied adhesive into the joint. In one example, the mixture of adhesive and sawdust may be allowed to partially cure prior to pressing. In one example, the pressing is accomplished by pounding the mixture into the joint using a mallet or the like. An amount of sawdust may be applied at block 1230 such that the pressed-in mixture is substantially flush with the joint surface and such that the joint is densely packed with the pressed-in sawdust. Once the sawdust and adhesive have been pressed-in, the method continues at block 1250 .
[0117] Block 1250 typically indicates allowing the pressed-in mixture of adhesive and sawdust to cure. Once the pressed-in mixture has cured, the method continues at block 1250 .
[0118] Block 1250 typically indicates finishing the joint. In one example, the finishing is accomplished by sanding the joint such that the appearance and texture of the joint is consistent with the appearance and texture of the joint surface. In another example, the finishing is accomplished by distressing the joint and the joint surface with a chainsaw or the like resulting in an overall appearance and texture of a rough-hewn log. | Techniques for building construction using fabricated timbers. In one example, such timbers are fabricated using conventional 2× (two-by) lumber to produce a square log appearance. These fabricated timbers are stacked to form outside and/or inside walls. The fabricated timbers and walls are configured to sustain desired vertical and lateral loads anticipated of a building such as a cabin, home, garage, barn, office building, or the like. A building constructed using such timbers appears to be built of square logs. Fabricated timber construction, as compared to conventional log or stick-frame construction, provides the appearance of high-quality log construction at a far lower cost, with higher R-values and appraised values, and is also far lower in cost and much simpler than conventional stick-frame construction. | 4 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for providing an insensitive munition, and more particularly to a heat sensitive case/nozzle and case/closure interface of a pressure vessel which separates on the application of high external heat such that the pressure vessel, for example a rocket motor, will fail at a temperature lower than the auto-ignition temperature of the propellant in the rocket motor.
BACKGROUND OF THE INVENTION
The inadvertent ignition or explosion of a munition such as a rocket motor could present a severe hazard. The inadvertent firing or ignition could result when high external heat is applied to the munition, for example, when it is surrounded by fire. The present invention is directed to alleviating this problem by destroying the integrity of the pressure vessel of the munition when external heat is applied. For example, in a rocket motor, the structural integrity of the case to nozzle interface is made to fail at a temperature lower than the auto-ignition temperature of the propellant of the rocket. By separating the nozzle from the rocket case, the throat area of the aft opening of the case without the nozzle is increased significantly resulting in a low operating pressure of the rocket motor even if the propellant were to ignite. The thrust of the motor would be very low, and accordingly would no longer present a hazard.
Accordingly, it is an object of this invention to provide a new and improved method and apparatus for destroying the integrity of the pressure vessel of the munition when external heat is applied prior to reaching the firing temperature or auto-ignition temperature of the propellant of the munition.
A still further object of this invention is to provide a new and improved method and apparatus for providing an insensitive munition which is simple in implementation, inexpensive, and reliable.
SUMMARY OF THE INVENTION
In carrying out this invention, in one illustrative embodiment thereof, an insensitive propellant-loaded munition is provided having a heat sensitive case/nozzle interface which loses structural integrity when heated to a predetermined temperature comprising the steps of interfacing a munitions case and a nozzle with aligned grooves in the case and nozzle; arranging a plurality of holes spaced radially around and in communication with the aligned grooves of the interface; housing an internal spring retainer and a solidified fusible material in the aligned grooves which fusible material melts at a predetermined temperature lower than the auto-ignition temperature of the propellant-loaded munition; and loading the spring retainer in the aligned grooves whereby the loaded spring retainer and solidified fusible material maintain the structural integrity of the case/nozzle interface such that when the predetermined melt temperature of the fusible material is reached the solidified fusible material melts and the spring retainer returns towards its unloaded state and forces the melted fusible material through the radial holes from the grooves thereby separating the nozzle from the case at the interface.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with further objects, aspects, features and advantages thereof will be more clearly understood from the following description taken in connection with the accompanying drawings in which like elements are designated with the same reference numbers throughout the various views.
FIG. 1 is a cross sectional view illustrating the case to nozzle interface being retained by an internal retainer.
FIG. 2 is an enlarged cross sectional view of the interface area of FIG. 1 showing the retainer in an initial position during the assembly of the nozzle to the case.
FIG. 3 is an enlarged cross sectional view similar to FIG. 2 illustrating the tightening sequence of the retainer which is shown in a final position for securing the case and nozzle together.
FIG. 4 is a cross sectional view similar to FIG. 3 illustrating the method step in accordance with the present invention of filling the remaining space in a casing groove with fusible alloy when set screws are removed.
FIG. 5 is a cross sectional view of another embodiment of the rocket motor of FIG. 1 which includes a forward retainer and forward closure fabricated in the same manner as the nozzle/case interface.
FIG. 6 is an enlarged cross sectional view similar to FIG. 4 showing another embodiment of the case to nozzle interface.
FIG. 7 is an enlarged cross sectional view of another embodiment showing the interface area during assembly.
FIG. 8 is similar to FIG. 7 showing the interface in operative position.
FIG. 9 illustrates the case/nozzle interface after being exposed to a predetermined temperature.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a pressure vessel or munition, referred to generally with the reference numeral 10, includes a pressure vessel such as a rocket motor case 12 housing a rocket propellant 14 of a suitable polymer matrix which is ignited by conventional means (not shown). A nozzle 22 is retained on or secured to the case 12 by an internal spring retainer 25, such as spring steel, steel alloy, beryllium copper, aluminum alloys, reinforced plastic or any other suitable material that can satisfy the design requirements. A primary objective of the present invention is to provide an insensitive munition 10 by providing a method for destroying the structural integrity of the pressure vessel 10 when external heat is applied, such as when the munition 10 is surrounded by fire. The idea is that the munition 10 should fail at a temperature lower than the auto-ignition temperature of the propellant 14. In the present invention, the munition 10 is designed to lose the structural integrity of the case to nozzle interface 21. If the nozzle 22 separates from the case 12, the throat area of the aft opening of the case 12 without the nozzle 22 will be increased significantly resulting in a very low operating pressure for the munition 10 even if the propellant 14 were to ignite. Accordingly, the thrust of the rocket 10 would be so low as to not present a hazard.
The method of eliminating the integrity of the interface 21 between the case 12 and the nozzle 22 will first be described in one embodiment in reference to FIG. 2 in which a retainer 25 preloaded for positioning in case groove 16 is positioned in its original initial position during assembly of the nozzle 22 to the case 12 in case groove 16. Holes 18 drilled in the circumferential periphery of the rocket case 12 and radially aligned with case groove 16 contain set screws 20. The nozzle 22 is provided with a mounting groove 24 which is placed in alignment with case groove 16 of the case 12 when the nozzle 22 is mounted on the case 12. The nozzle 22 also contains an O-ring groove 26 containing an O-ring 28 which will seal the interface area 21 between the rocket case 12 and the nozzle 22. FIG. 2 illustrates the spring retainer 25 in its initial preloaded position in case groove 16 during the assembly of the nozzle 22 to the case 12. The set screws 20 are backed out so that the spring retainer 25 is generally out of contact with the set screws when the retainer 25 is placed in the case groove 16. The retainer 25 is preloaded against the outside diameter of case groove 16 in the case 12 which preloading urges the spring retainer 25 into a larger diameter when in its unrestricted free state then when in its loaded state.
In FIG. 3, the set screws 20 located circumferentially around the case 12 are screwed in gradually in a suitable tightening sequence ultimately placing a part of the retainer 25 in the mounting groove 24 of the nozzle 22 which effectively secures the nozzle 22 to the case 12.
Once the retainer 25 is in its final position, as shown in FIG. 3, less set screws 20 are required to hold the retainer 25 in place than compared with the number of set screws required to bring the retainer 25 into place straddling the mounting groove 24 and the case groove 16. Accordingly, some of the set screws are removed and a liquid, low-melt temperature fusible composition, preferably a metal alloy, is then cast into the vacated holes filling the remaining space in the case groove 16 as illustrated in FIG. 4. Other fusible compositions or materials can be used such as plastics, waxes and others. If desired or required, additional small sprue holes may be provided through case 12 circumferentially and radially around the case groove 16 to aid in the casting process.
Metal alloys that would be ideal for this application are fusible alloys, such as for example, those alloys which may be composed of various percentages of one or more of tin, lead, bismuth and cadmium. Such metal alloys would generally be designed to have melt temperatures in the range of about 150° to about 330° F., which melt temperature is primarily dependent upon the composition of the metal alloys. Of course, the melting temperature of the fusible composition or material to be employed will depend on the particular application. As pointed out, the melt temperature of the fusible composition employed should be lower than the firing or auto-ignition temperature of the propellant so the design of the melt temperature will depend on the firing or auto-ignition temperature of the propellant for a particular application. A specific example of a useful low-temperature metal alloy is, for example, an alloy containing about 22% tin, about 50% bismuth and about 28% lead which will melt in the range of about 205° to about 230° F. The invention is not considered limited to this particular example, and the type of fusible material used will depend on the application.
After the fusible material 30 shown in FIG. 4 solidifies, the remaining set screws are removed and the assembly is complete. If desired, the remaining removed set screw holes may also be filled with fusible material. When in the field, if the case 12 were to be exposed to a high ambient temperature, for example a high temperature caused by fire, the solidified fusible material 30 will melt and the preload of the spring retainer 25 will push the melted or liquid fusible material 30 out of the set screw holes 18 or any sprue holes if so provided. The spring retainer 25 will then return toward its original unrestricted free state position as shown in FIG. 2 and consequently, the nozzle 22 will virtually fall off rendering the rocket motor 10 safe.
In rocket motor applications where there is still too much thrust even without the nozzle 22 in place, a similar retainer assembly 32 may be used to hold a forward closure 34 in place on the case 12 as shown in FIG. 5.
The method of eliminating the integrity of an interface between case 12 and forward closure 34 is similar to that described for the case/nozzle interface. A spring retainer assembly 32 comprises a second spring retainer preloaded for positioning in and positioned in a second circumferential mounting groove in the case 12. The forward closure 34 is provided with a groove which is placed in alignment with the second case mounting groove. The forward closure 34 is mounted on case 12 with the preloaded second spring retainer positioned in its original position in the second case mounting groove. Set screws of the retainer assembly 32 are located circumferentially in the case 12 and radially around the second mounting groove. The second spring retainer is preloaded against the outside diameter of the second mounting groove in case 12 which preloading urges the second spring retainer into a larger diameter when in its unrestricted free state.
Set screws located circumferentially around case 12 are screwed in gradually in a suitable tightening sequence ultimately placing a part of the second spring retainer in the forward closing groove which effectively secures the forward closure 34 to the case 12.
Once the second retainer is in its final position less set screws are required to hold the retainer in place than compared with the number of set screw required to bring the retainer into place straddling the second case mounting groove and the forward closure groove. Accordingly, some of the set screws are removed and a liquid, low-melt temperature fusible material is then cast into the vacated holes filling the remaining space in the second case mounting groove. If desired or required, additional small sprue holes may be provided through the case circumferentially around the second mounting groove to aid in the casting process. The fusible material may be the same or different from the fusible material used to secure the nozzle 22 to the case 12.
After the fusible material solidifies, the remaining set screws are removed and the forward closure assembly is complete. If desired, the remaining removed set screws holes may also be filled with fusible material. When in the field, if the case 12 were to be exposed to a high ambient temperature, for example a high temperature caused by fire, the solidified fusible material will melt and the preload of the second spring retainer will push the melted or liquid fusible material out of the set screw holes or any sprue holes if so provided. The second spring retainer will then return toward its original unrestricted free state position in the second case mounting groove and consequently, the forward closure 34 will virtually fall off rendering the rocket motor 10 safe.
With both ends, i.e. the forward closure 34 and nozzle 22, of the motor case 12 removed, the rocket munition 10 will not have a tendency to thrust in either direction thereby rendering the munition insensitive if it is inadvertently ignited from an external heat source.
As will be seen in FIG. 5, the nozzle 22 and/or forward closure 34 slide into the case 12. It will be appreciated that the nozzle and/or forward closure may also fit over either end or both ends of the case 12.
In the embodiment shown in FIG. 6, the spring retainer 25 is positioned in a groove in the case 12 instead of in the nozzle 22 and/or front closure 34 as shown in FIGS. 1-5. The action of the spring retainer 25 is reversed. The spring retainer is preloaded to a larger diameter than when the retainer is in a free state. The meltable or fusible material 30 in solid form occupies the enlarged groove area next to the inside of the spring retainer 25. Accordingly, when heated the spring retainer 25 reduces its diameter and releases the nozzle in the embodiment of FIG. 6.
Although the cross-section of the spring retainer 25 and grooves are shown in substantially rectangular form and ,, substantially rectangular form is preferred, it will be appreciated that either or both the retainer and grooves may vary in shape in any suitable form which operate within the spirit of the invention.
In another embodiment as illustrated in FIGS. 7-9 instead of casting a fusible material into the case or nozzle grooves, a strip of fusible material 36 is placed in the case groove 16 as shown in FIG. 7 prior to assembly of the munition. The spring retainer 25 is placed in and fills groove 24 in the nozzle 22.
When assembled as shown in FIG. 8, the spring retainer 25 springs out against the strip of fusible material 36 in the case groove 16. If the assembled interface 21 is exposed to a temperature which exceeds the predetermined melt temperature of the strip of fusible material 36, the strip 36 melts and the spring retainer 25 expands until filling the groove 16 in the case 12 while forcing the liquid fusible material 36 out of the radial holes 18 as shown in FIG. 9.
Accordingly, a very effective method for eliminating the integrity of the joint between a case and nozzle of a munition is described reducing the hazards involved from external causes, such as for example, from ambient heat when the munition is surrounded by fire. A reliable, easy to fabricate method and apparatus are provided which separate munition components to prevent uncontrolled thrust if it auto-ignites and, when necessary, such separation may occur both fore and aft of the munition case.
Since various other changes and modifications to fit the particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the examples chosen for purposes of illustration, and includes all changes and modifications which do not constitute a departure from the true spirit and scope of this invention as claimed in the following claims and equivalents thereto. | A heat sensitive case/nozzle interface is provided for an insensitive propellant-loaded munition such that the interface loses its structural integrity when high external heat is applied. The joint between a rocket case housing a rocket motor and nozzle forming the interface is received by an internal spring retainer positioned in a first groove in the case or nozzle in cooperation with a fusible material housed in an aligned second groove in the nozzle or case, respectively. A plurality of aligned openings extend into said first and second grooves. When the rocket is exposed to a high ambient temperature greater than melt temperature of the fusible material but lower than the auto-ignition temperature of the rocket, the fusible material melts and is forced through said holes by the spring retainer permitting the nozzle to separate from the case rendering the rocket motor safe if it auto-ignites. | 8 |
FIELD
The present disclosure relates to a cooling system compressor and, more particularly, to a cooling system with a variable operating range.
BACKGROUND
This section provides background information related to the present disclosure which is not necessarily prior art.
A cooling system (i.e., air conditioning system or refrigeration cycle) typically includes a compressor, a condenser, an expansion valve assembly, and an evaporator. The cycle also includes a plurality of conduits that fluidly connect the compressor, condenser, expansion valve assembly, and evaporator. A refrigerant flows through the conduits and through the compressor, condenser, expansion valve assembly, and evaporator cyclically, changing temperature and pressure through the cycle. Moreover, air flows past the evaporator to be cooled, and this cooled air can be used to cool a control space (e.g., a passenger compartment of a vehicle, a building, etc.). Also, air flows past the condenser to be heated.
In many cooling systems, the compressor operates as long as the evaporator temperature (e.g., temperature at an evaporator fin) is within a fixed temperature range. For instance, the compressor remains ON as long as the actual evaporator temperature is between an upper limit and a lower limit. If the actual evaporator temperature is outside the upper or lower limits, then the compressor automatically turns OFF. This approach can avoid freezing of the evaporator.
The following discloses a cooling system with a compressor that can operate according to variable evaporator temperature limits. This approach can improve efficiency of the cooling system in some conditions.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
A method of operating an air conditioning system having a compressor and an evaporator that are operably connected is disclosed. The method includes changing output of the compressor based on a temperature limit of the evaporator. The temperature limit is one of a predetermined fixed temperature limit and a variable temperature limit. The method also includes determining the variable temperature limit by determining a target air outlet temperature for conditioned air in a control space, detecting an actual evaporator temperature, calculating a difference between the target air outlet temperature and the actual evaporator temperature, finding a predetermined first temperature adjustment that correlates to the difference, finding a predetermined second temperature adjustment that correlates to another condition, and calculating the variable temperature limit by adjusting the fixed temperature limit by one of the first and second temperature adjustments.
An air conditioning system that cools a control space is also disclosed. The system includes an evaporator having a temperature sensor that detects an actual evaporator temperature. The system also includes a compressor that is operably coupled to the evaporator. Furthermore, the system includes a controller that changes output of the compressor based on a comparison between the actual evaporator temperature and a temperature limit. The temperature limit is one of a predetermined fixed temperature limit and a variable temperature limit. The controller is operable to determine a target air outlet temperature for conditioned air in the control space, calculate a difference between the target air outlet temperature and the actual evaporator temperature, find a predetermined first temperature adjustment that correlates to the difference, find a predetermined second temperature adjustment that correlates to another condition, and calculate the variable temperature limit by adjusting the fixed temperature limit by one of the first and second temperature adjustments.
Furthermore, a method of operating an air conditioning system of a vehicle is disclosed, wherein the air conditioning system has a compressor and an evaporator that are operably connected, and wherein the vehicle includes an engine and a windshield. The method includes turning the compressor ON and OFF based on a comparison of an actual evaporator temperature and a temperature limit. The temperature limit is one of a predetermined fixed temperature limit and a variable temperature limit. The method includes determining the variable temperature limit by determining a target air outlet temperature for conditioned air in a control space, wherein the target air outlet temperature based on an ambient temperature outside the control space, a user setting of a desired control space air temperature, an actual air temperature inside the control space, and a sun load on the control space. The variable temperature limit is also determined by detecting the actual evaporator temperature calculating a difference between the target air outlet temperature and the actual evaporator temperature, finding a predetermined first temperature adjustment that correlates to the difference, finding a predetermined second temperature adjustment that correlates to the ambient temperature outside the control space, applying a time constant to a lesser of the first and second temperature adjustment, and calculating the variable temperature limit by adjusting the fixed temperature limit by the time-constant-applied lesser of the first and second temperature adjustment.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is a schematic illustration of a cooling system according to various exemplary embodiments of the present disclosure;
FIG. 2 is a flowchart illustrating a method of operating the cooling system of FIG. 1 ;
FIG. 3 is a graph of evaporator temperature limits for determining operation of a compressor in the cooling system of FIG. 1 ;
FIG. 4 is a graph of first temperature adjustment for determining operation of the compressor in the cooling system of FIG. 1 ;
FIG. 5 is a graph of second temperature adjustment for determining operation of the compressor in the cooling system of FIG. 1 ; and
FIG. 6 is a graph of a time-constant-applied temperature adjustment for determining operation of the compressor in the cooling system of FIG. 1 .
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Referring initially to FIG. 1 , a cooling system 10 is illustrated according to various exemplary embodiments. As shown, the cooling system 10 can include a condenser 12 , an expansion valve 14 , an evaporator 16 , a compressor 18 , and a plurality of conduits 19 (e.g., pipes, tubes, etc.). In some ways, the cooling system 10 can operate similar to known cooling systems. Specifically, a refrigerant or coolant (e.g. Freon, R-410A, etc.) can flow through the conduits 19 and through the compressor 18 , condenser 12 , expansion valve 14 , and evaporator 16 cyclically, changing temperature and pressure through the system 10 . In some embodiments, the evaporator 16 can include a plurality of fins (not shown) over which air flows to be cooled, and this cooled air is introduced into a control space 20 (indicated in FIG. 1 by a box with broken lines) to thereby cool the control space 20 . Also, air can flow past the condenser 12 to be heated to remove heat therefrom.
The cooling system 10 can be suitable for use in a vehicle (e.g., car, van, etc.), in a building, or in any other area. For purposes of discussion, the cooling system 10 will be discussed as if it is incorporated within a vehicle, and the control space 20 will be discussed as a passenger compartment of the vehicle.
The system 10 can include a control space temperature sensor 22 . The sensor 22 can include a thermometer, a thermister, a thermocouple, or any other suitable sensor 22 that can detect the actual air temperature within the control space 20 .
The system 10 can further include an evaporator temperature sensor 24 . The sensor 24 can include a thermometer, a thermister, a thermocouple, or any other suitable sensor 24 that can detect the actual temperature at the evaporator 16 , detect the temperature of the air passing over and cooled by the evaporator 16 , etc. The temperature sensor 24 can be coupled directly to an outer surface of one of the fins to thereby determine the actual temperature of the evaporator 16 . Also, in some embodiments, the temperature sensor 24 can be disposed within the airstream passing over the evaporator 16 to thereby detect the temperature in the airstream.
The system 10 can additionally include an engine temperature sensor 25 . The sensor 25 can be of any suitable type (e.g., thermometer, thermister, etc.) for detecting the temperature of the engine. The sensor 25 can detect the temperature of the engine in any suitable fashion. For instance, the sensor 25 can detect the temperature of the engine coolant at any suitable location relative to the engine (e.g., in a coolant jacket, adjacent a combustion chamber, or immediately downstream of the coolant jacket). As will be discussed in detail below, the sensor 25 can be used to ensure that the engine is warmed up and that it is at a state of relative equilibrium.
Moreover, the system 10 can further include an ambient temperature sensor 26 . The sensor 26 can include a thermometer, a thermister, a thermocouple, or any other suitable sensor 26 that can detect an actual ambient temperature outside the control space 20 .
Additionally, the system 10 can include a sun load sensor 28 that detects the sun load on the control space 20 . In some embodiments, the sun load sensor 28 is light sensitive. Thus, as the control space 20 is exposed to more light (e.g., high sunlight levels), the sun load sensor 28 can detect increased sun load on the control space 20 , and conversely, as the control space 20 is exposed to less light (e.g., low sunlight levels), the sun load sensor 28 can detect reduced sun load on the control space 20 .
Still further, the system 10 can include a controller 30 . The controller 30 can be a computerized device having a processor 32 , a memory device 34 (RAM and/or ROM), computerized logic, other hardware and software, etc. The memory device 34 can have various data stored thereon in any suitable form, such as the graphical data represented in FIGS. 3-6 (described below). The controller 30 can be in communication with the thermal sensors 24 , 22 , 26 , the sun load sensor 28 , and the coolant temperature sensor 25 to gather respective data. Also, as will be discussed, the controller 30 can control operations of various components of the system 10 , including the compressor 18 for operating the system 10 . For instance, the controller 30 can control output of the compressor 18 (e.g., turn the compressor 18 ON and OFF, change the power consumption of the compressor 18 , etc.) for operating the system 10 and maintaining the control space 20 at a desirable air temperature.
The controller 30 can be in communication with various user controls 36 , which can be used by the user for inputting various control commands for operating the system 10 . It will be appreciated that the user controls 36 can include buttons, knobs, sliders, switches, or any other input device for inputting the user's control commands.
For instance, the user controls 36 can include an ON/OFF switch 38 for manually turning the system 10 ON and OFF. The user controls 36 can also include a temperature setting control 42 for manually inputting a user-desired temperature for the control space 20 . Furthermore, the user controls 36 can include blower controls 40 . The blower controls 40 can include a switch for changing a blower speed. Also, the blower controls 40 can include switches for changing the mode or direction of airflow within the control space 20 . For instance, the blower controls 40 can be used to direct air generally toward a passenger's face (face mode), toward the passenger's feet (feet mode), toward both the face and feet (bi-level mode), and/or toward the windshield or windscreen (defog or defrost mode). It will be appreciated that the face, feet, and bi-level modes can be generally selected by the user during normal driving, and the defog mode can be generally selected by the user if the windshield or windscreen is fogged up, has accumulated frost, etc. It will also be appreciated that there could be several de-fog modes, such as a “foot-defog mode” in which air is directed to both the user's feet and windshield, and a “defog mode” in which air is primarily directly only to the windshield. The air-conditioning system can also include a “purge mode” or “initialization mode,” in which air is substantially supplied only to the feet of the user, and which occurs upon initial startup of the system 10 .
As will be discussed, the controller 18 can automatically control the compressor 18 according to a number of variables. For instance, the controller 18 can change the output of the compressor based on temperature limits of the evaporator 16 (i.e., based on a comparison between the actual evaporator temperature detected by the sensor 24 and one or more temperature limits). These temperature limits can be saved on the memory device 34 of the controller 30 . For instance, FIG. 3 represents various temperature limits, including predetermined fixed temperature limits (represented by solid lines) and variable temperature limits (represented by broken lines).
The fixed temperature limits can be predetermined by testing under various driving conditions and saved on the memory device 34 . In the embodiments shown in FIG. 3 , a fixed lower limit can be set at 2.5° C., and a fixed upper limit can be set at 3.5° C. (It will be appreciated that these fixed lower and upper limits can have any suitable value).
The variable temperature limits (shown in broken lines) can be calculated by the controller 30 by adjusting the fixed temperature limits in a manner to be discussed. Specifically, in the embodiment of FIG. 3 , the lower fixed temperature limit of 2.5 is adjusted by 0.1° C. such that the variable lower temperature limit is 2.6° C., and the upper fixed temperature limit 3.5° C. is adjusted by 0.1° C. such that the variable upper temperature limit is 3.6° C. It will be appreciated that the amount of adjustment can have any suitable value. It will also be appreciated that the variable temperature limits can be less than the respective fixed temperature limit.
Thus, the controller 30 can turn the compressor 18 ON if the actual evaporator temperature detected by sensor 24 is between these upper and lower limits, and the controller 30 can turn the compressor 18 OFF if the actual evaporator temperature is above the upper limit or below the lower limit. Specifically, under certain conditions, the controller 30 can turn the compressor 18 ON if the actual evaporator temperature is between the fixed limits (i.e., between 2.5 and 3.5° C.). This can reduce the likelihood of the evaporator freezing. Under other conditions, the controller 30 can turn the compressor 18 ON if the actual evaporator temperature is between the variable limits (i.e., between 2.6 and 3.6° C.). This can reduce the likelihood of the evaporator freezing and also provide for improved efficiencies and fuel savings.
Referring now to FIG. 2 , a method 50 of operating the cooling system 10 will be discussed according to various exemplary embodiments. As shown, the method 50 can begin in step 52 , in which the air conditioning system 10 has been turned on by the user.
Then, in block 54 , the evaporator temperature sensor 24 detects the actual temperature of the evaporator 16 . Block 54 can include taking raw temperature data or can include filtering the temperature data gathered by the sensor 24 . In the latter case, the temperature data can be filtered by detecting the temperature several times and averaging the results.
Subsequently, in block 55 , a target air outlet temperature can be determined. In other words, the controller 30 can determine how cold the air entering the control space 20 should be. The target air outlet temperature can be determined according to programmed logic (e.g., an algorithm) loaded on the controller 30 . The processor 32 can compute the target air outlet temperature according to one or more factors. For instance, this target air outlet temperature can be determined according to the user's desired control space air temperature (i.e., the temperature set using the temperature setting controls 42 ). The target air outlet temperature can also be determined according to the ambient temperature detected by the sensor 26 , the actual temperature inside the control space 20 detected by the sensor 22 , and/or the sun load detected by the sensor 28 . One or more of these variables and/or other variables can be used in a known algorithm by the processor 32 to determine the target air outlet temperature in block 55 .
Next, in block 56 , the blower mode of the system 10 is determined. Specifically, it can be determined whether the blower control 40 is set to defog mode or purge mode (described above). If the blower control 40 is set to face, feet, or bi-level (i.e., block 56 answered negatively), then block 58 follows; however, if the blower control 40 is set to defog or purge mode (block 58 answered affirmatively), then block 70 follows.
In block 58 , the engine temperature sensor 25 detects the temperature of the engine, and it is determined whether the coolant temperature is less than a predetermined temperature limit. The limit can have any suitable value. In some embodiments, the limit can be between approximately seventy and ninety degrees Celsius (70° C.-90° C.). Also, in some embodiments, the limit can be approximately eighty degrees Celsius (80° C.). If the temperature detected by the sensor 25 is above the limit (block 58 answered negatively), then block 60 follows; however, if the temperature detected by the sensor 25 is below the limit (block 58 answered affirmatively), then block 70 follows.
In block 60 , the controller 30 finds a first temperature adjustment for adjusting the fixed temperature limit described above with respect to FIG. 3 . The first temperature adjustment can be a predetermined value included in a lookup table, in a graph, or otherwise saved on the memory device 34 . For instance, as shown in FIG. 4 , the processor 32 can calculate the difference between the target air outlet temperature (TAO) (determined in block 55 ) and the actual evaporator temperature (TE(f)) (detected in block 54 ). For instance, as shown in FIG. 4 , the target air outlet temperature (TAO) can be 15 degrees, and the actual evaporator temperature (TE(f)) can be approximately 7 degrees. Thus, according to the graph of FIG. 4 , the difference between TAO and TE(f) would be 8° C., and the corresponding first temperature adjustment (f(offset)) would be approximately 1.5° C.
Referring back to FIG. 2 , the method 50 can continue in block 62 . In block 62 , the controller 30 finds a second temperature adjustment for adjusting the fixed temperature limit described above with respect to FIG. 3 . The second temperature adjustment can be a predetermined value included in a lookup table, in a graph, or otherwise saved on the memory device 34 . More specifically, the second temperature adjustment can be determined according to the ambient temperature detected by the sensor 26 . Thus, as shown in FIG. 5 , the ambient temperature sensor 26 could detect an ambient temperature of 20° C., and the corresponding second temperature adjustment (f(Tam)) would be approximately 3° C.
Subsequently, in block 64 , the controller 30 compares the first temperature adjustment (found in block 60 ) and second temperature adjustment (found in block 62 ) to identify which is the lesser of the two. In the example embodiments given above, the first temperature adjustment is 1.5° C., and the second temperature adjustment is 3° C. Thus, the lesser of the two (f(CompOffset)) is the first temperature adjustment or 1.5° C.
Next, in block 66 , the controller 30 applies a time constant to the temperature adjustment identified in block 64 . In some embodiments, the time constant is applied according to a lookup table, a graph, or other data saved on the memory device 34 . Specifically, in the examples given above, block 64 resulted in a temperature adjustment of 1.5° C. Thus, FIG. 6 shows the temperature adjustment with applied time constant (f(CompOffset)_tau) for 1.5° C. At a time constant of 30 seconds, the temperature adjustment with applied time constant (f(CompOffset)_tau) is equal to 0.1° C. (It will be appreciated that the time constant applied could be other than 30 seconds.)
Then, in block 68 , the fixed temperature limits are adjusted by f(CompOffset)_tau. Thus, the lower fixed limit of 2.5° C. of FIG. 3 is adjusted (increased) to 2.6° C., and the upper fixed limit of 3.5° C. is adjusted (increased) to 3.6° C. Thus, as discussed above, if the actual evaporator temperature detected by the sensor 24 is between 2.6° C. and 3.6° C., the compressor 18 will remain ON, but the compressor 18 will shut OFF if the actual evaporator temperature is outside the 2.6-3.6° C. temperature range.
Referring back to FIG. 2 , if block 56 or block 58 is answered affirmatively, then the fixed temperature limits are used. Thus, if the actual evaporator temperature detected by the sensor 24 is between 2.5° C. and 3.5° C., the compressor 18 will remain ON, but the compressor 18 will shut OFF if the actual evaporator temperature is outside the 2.5-3.5° C. temperature range. Accordingly, if the air conditioning system 10 is in defogging or purge mode (block 56 answered affirmatively) or the engine has not sufficiently warmed up (block 58 answered affirmatively), the method 50 will not adjust the temperature limits.
As shown in FIG. 2 , the previous blocks will repeat in a loop until the air conditioning system 10 is switched off. Specifically, in block 72 , it is determined whether the ON/OFF switch 38 has been switched OFF. If the switch 38 remains ON, then the method 50 repeats to block 54 , but if the switch 38 is moved OFF, then the method 50 is finished.
Accordingly, the system 10 and method 50 discussed above can reduce compressor usage and, hence, improve fuel economy. Also, the temperature limits can be adjusted repeatedly, depending on instant conditions. Moreover, the driving conditions can vary the temperature limits based on loads on the system 10 , and the system 10 can quickly react to changes in driving conditions.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention. | A method of operating an air conditioning system includes changing output of the compressor based on a temperature limit of the evaporator. The temperature limit is one of a predetermined fixed temperature limit and a variable temperature limit. The method also includes determining the variable temperature limit by determining a target air outlet temperature for conditioned air in a control space, detecting an actual evaporator temperature, calculating a difference between the target air outlet temperature and the actual evaporator temperature, finding a predetermined first temperature adjustment that correlates to the difference, finding a predetermined second temperature adjustment that correlates to another condition, and calculating the variable temperature limit by adjusting the fixed temperature limit by one of the first and second temperature adjustments. | 5 |
BACKGROUND
[0001] It is desirous in obtaining sample cores from bore holes to know the direction that certain parts of the core bear with relation to the surface of the ground where the bore has been made. To accomplish this, complicated mechanisms have heretofore been used. An example is a mechanism including, for instance, a compass and photographic equipment. One disadvantage in such a mechanism is that the drilling operation sends vibrations through the coring equipment and drilling fluid. The vibrations tend to blur the photographs, making it necessary to completely halt the drilling and fluid pumping operations and allow the vibrations to subside, which consumes time, to obtain a clear photograph.
[0002] Further, with the use of a compass, the apparatus and the ground material must be non-magnetic so that the compass will not be affected. One such mechanism is shown in U.S. Pat. No. 3,450,216 dated Jun. 17, 1969. It is also known for core taking apparatus to include a core barrel attached to the bottom end of the drill string and isolated from the rotation by bearings. In such an arrangement, friction between the core and core barrel provides the only force holding the core barrel from rotating. Such an apparatus is shown in U.S. Pat. No. 3,004,614. If, however, the core should break, the core barrel will rotate, and all orientation will be lost. In fact, many prior core sampling apparatus rely on the integrity of the core.
[0003] It is also known to score the core with internally extending projections, such as, for example, as shown in U.S. Pat. No. 1,701,784. One disadvantage with such projections is that they have been evenly spaced around the core barrel, and thus the orientation of the core may not be accurately ascertained. A further disadvantage is that sometimes the projections fail to adequately score the core.
[0004] Another disadvantage of conventional coring device is that such devices are prone to inner rod failure due to clogging at the bottom of the coring device. Conventional coring devices, such as the coring device 100 shown in FIG. 3, are double tube core barrels, with outer tubes 110 and inner tubes 111 mounted on separate bearing assemblies. The inner and outer tubes 110 , 111 do not rotate together. Through this arrangement, the amount of water contacting the core is minimized. Blockages sometimes occur during coring operations. A consequence of such blockages is that the inner orienting tubes 111 are prevented from rotating. The continued force of the motor used to rotate the inner orienting tubes 111 eventually leads to the breakage of the tubes 111 , thus destroying the orientation of the core.
SUMMARY
[0005] The invention provides a device for orienting a core cut in a bore hole. The device includes a plurality of orienting rod sections connected one to another into a rotatable orienting rod, and a core barrel attached to one end of the rotatable orienting rod. The core barrel is configured to receive the core and the core barrel includes a plurality of projections extending from an inward surface of the core barrel. At least three projections are grouped together on the inward surface opposite from a fourth projection.
[0006] The invention further provides a system for cutting a core in a bore hole. The system includes a driving means, a plurality of orienting rod sections connected together as an orienting rod, the orienting rod being rotatable by the driving means, a core barrel attached to one end of the orienting rod, and a ratchet assembly for protecting the orienting rod from breakage caused by a clog in said core barrel.
[0007] The invention also provides a method for obtaining a cut core from a bore hole. The method includes the steps of extending a rotatable orienting rod, with a core barrel attached thereto, into the bore hole, cutting the core, depositing the core in the core barrel, and scribing the core with a plurality of grouped projections and one opposing projection located on an inner surface of the core barrel.
[0008] The foregoing and other advantages and features of the invention will be more readily understood from the following detailed description of the invention, which is provided in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a cross-sectional view of a coring device constructed in accordance with an embodiment of the invention.
[0010] [0010]FIG. 2 is an enlarged cross-sectional view of a portion of the device of FIG. 1.
[0011] [0011]FIG. 3 is an enlarged cross-sectional view of another portion of the coring device of FIG. 1.
[0012] [0012]FIG. 4 is an enlarged view of the portion of the device within circle IV of FIG. 1.
[0013] [0013]FIG. 5 is an enlarged view of the portion of the device within circle V of FIG. 1.
[0014] [0014]FIG. 6 is a cross-sectional view along line VI-VI of FIG. 4.
[0015] [0015]FIG. 7 is an elevation view partly in cross-section showing the entire coring device in use downhole.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] Referring to FIG. 7, a drill pipe assembly 9 formed in several sections and suitably secured together, includes drill rods, outer barrels and an inner core taking means. As shown, the drill rods are rotated by a suitably powered rotary spindle 10 . The remainder of the operating rig is completed with a suitable support structure, such as a derrick D, and a source of drilling fluid directed by a drilling fluid swivel 76 , together with an engine, a water pump and a drum hoist (not illustrated).
[0017] With specific reference to FIGS. 1 - 6 , an inner core taking means is shown including a plurality of sections 11 a (FIGS. 1 - 3 ) which are keyed together to form an orienting rod 11 . At the working end of the orienting rod 11 , a core receiving barrel 12 is rotationally and axially secured (FIGS. 1, 2 and 4 ). The core receiving barrel 12 carries scribing means 13 a , 13 b , 13 c (FIGS. 4, 6), and 13 d (FIG. 6) on an inner surface thereof. The scribing means 13 a - d may be projections which are configured to scribe marks in a core section, or the scribing means 13 a - d may be another suitable configuration. As the core is cut and moves into a center area 15 of the core receiving barrel 12 , marks or grooves are scribed into the outer surface of the core which are intended to extend generally axially of the core. As shown in FIG. 6, the scribing means 13 a is opposite (180 degrees) from the scribing means 13 d and the scribing means 13 b and 13 c are grouped together and flank the scribing means 13 a . Through this arrangement, determining the orientation of a core is rendered more accurate. In practice, scribing means do not always produce scribe marks on cores, and so the presence of three such scribing means 13 a - c on one side and another scribing means 13 d on an opposing side of the core receiving barrel 12 allows one examining the core to piece together partial scribe marks from all of the scribing means 13 a - d to ascertain the proper orientation of the core.
[0018] The core receiving barrel 12 has a generally closed upper end and through this end there is an axially drilled, keyed bore 17 . The lower end of the orienting rod 11 as shown in FIG. 2 is threaded, and this threaded portion 16 passes through the bore 17 with a key 18 securing the core receiving barrel 12 against rotation. A pair of nuts 21 and 22 secure the barrel 12 in an axially adjustable position. The head of the core barrel 12 is provided with a plurality of small conduits 27 that extend upwardly and radially outwardly into a groove 28 which is closed by means of an O-ring 29 . Thus, if any drilling fluid is trapped in the core barrel 12 , it may pass by virtue of its pressure through these conduits 27 and 28 , and out past the O-ring 29 .
[0019] As has been mentioned, the orienting rod 11 is made up of a plurality of sections 11 a as necessary. For example, a first rod section 11 a is keyed to a second rod section 11 a by providing a socket 30 which receives a reduced end 31 of the second rod section 11 a , which is held in position by a holding screw 32 and keyed by a key 33 .
[0020] Surrounding the orienting rod 11 is a drill rod designated 40 which is illustrated as composed of several sections, each threadingly coupled together throughout the length as necessary. At one end of the drill rod section 40 , there is threadingly secured thereto an outer barrel head 50 a and an outer barrel 50 . At an end of the outer barrel 50 are cutting blades 51 (FIG. 4). The outer barrel 50 rotates, which allows the cutting blades 51 to cut the core which is received in the non-rotating core barrel 12 .
[0021] The outer barrel head 50 a is provided with threads 55 that threadingly engage the outer barrel 50 . The outer barrel head 50 a is provided with a central bore therethrough, and the central bore is counter-bored at counter-bore areas 56 and 57 . The counter-bore areas 56 , 57 receive, respectively, bearing units 58 and 59 . The orienting rod 11 is rotationally supported by these bearings 58 and 59 and is provided with means for stabilizing its axial position with an enlarged boss 60 having a seal 60 a and a nut 61 . The nut 61 also has a seal 61 a and is threadingly received on the threaded portions 16 of the orienting rod section 11 a . In addition, the outer barrel head 50 a includes means for allowing drilling fluid to pass therethrough and is provided with a plurality of axially extending bores 62 that connect via a groove 62 a to the open central portion of the drill rod assembly 9 . Lubrication of the bearings is readily provided by means of an axially extending bore 64 and a lateral passageway 65 which is fed through a grease fitting 66 in a fashion well known to those skilled in the art.
[0022] The outer barrel head 50 a is coupled to a portion of the drill rod section 40 by means of a connector 68 which has threads 69 and 69 a at either end thereof for engaging corresponding threads in the drill rod section 40 and the outer barrel head 50 a . The connector 68 is provided with a central bore therethrough which allows the passage of the orienting rod 11 as well as sufficient area for the passage of drilling fluid through the drill rod section 40 as will be explained in greater detail below. Each additional drill rod section 40 needed to provide the proper length may be coupled onto the drill rod section 40 and to each other by means of the same connector 68 , or by a different connector, as required.
[0023] In use, a driving means, namely the rotary spindle 10 (FIG. 7) at the upper end of the drill pipe assembly 9 , rotates the drill pipe assembly 9 as it is passed downhole into the ground to cut a core which passes into the center area 15 (FIGS. 1, 2). The core is scribed by the scribing means 13 a - d , one of which is oriented with a pointing device 38 having an arm 39 (FIGS. 1, 5). The pointing device 38 may be oriented in such a fashion that it will point to some certain predetermined position either fixed on the ground or to a certain compass bearing, such as to north or the like. For example, a pair of vertical posts 90 , 91 (FIG. 1) driven in the ground may maintain alignment. Thus, the core will be marked by reason of the alignment with one of the scribing means 13 a - d which may be differentiated from the other scribing means 13 a - 13 d so that it may be known how the core lines up with a certain location above ground. The arm 39 may extend outwardly between, for example, the vertical posts 90 , 91 so that it will maintain its position unless manually changed to orient the device in a different position. It should be appreciated that the device may be started at any point of orientation which is desirable. Further, if desired, the pointing device 38 and arm 39 may simply be left free and unrestrained with notations made of its compass bearing at various intervals during the coring operation. From the above, it will be apparent that the position of the scribes as received on the core is unaffected by interruptions in the coring operation or by breaks, seams, voids or any other faults that may exist in the material being cored.
[0024] With specific reference to FIG. 5, next will be described a ratchet assembly useful to suppress the breaking of the orienting rod 11 when a blockage is encountered at the working end of the drilling rod assembly 9 . As shown, a ratchet assembly 150 includes a first body 152 and a second body 162 . The first and second bodies 152 , 162 are retained to one another with a retaining pin 170 . The orienting rod 11 extends into the first body 152 . A turning rod 167 , which is rotated by the rotary spindle 10 , extends through the pointing device 38 through an opening 168 in the second body 162 . As will be described in greater detail below, the turning rod 167 rotates the first and second bodies 152 , 162 and thereby rotates the orienting rod 11 .
[0025] The first body 152 is cup-shaped having an open area 153 . A plate 160 is positioned within the open area 153 . The turning rod 167 extends through and is mounted to the plate 160 . The plate 160 includes a plurality of teeth 161 . The second body 162 also has a plurality of teeth 164 which mesh with the teeth 161 of the plate 160 . An O-ring 166 encircles the turning rod 167 within a cavity of the second body 162 .
[0026] A biasing mechanism is positioned in the first body 152 . Specifically, as shown in FIG. 5, a spring 154 is positioned within the open area 153 and extends toward the plate 160 . At one end of the spring 154 is a sphere 158 which contacts the plate 160 . At the other end of the spring 154 is a spring biasing member 156 . The spring biasing member 156 is tightened down to put a certain amount of force on the plate 160 such that the teeth 161 mesh with the teeth 164 during normal use but slip against each other when a clog at the working end of the drilling rod assembly 9 causes torsional forces on the orienting rod 11 . The rotary spindle 10 (FIG. 7) rotates the turning rod 167 , which in turn rotates the plate 160 . Under normal loading, the teeth 161 of the plate 160 mesh with the teeth 164 of the second body 162 , thereby causing rotation of the first and second bodies 152 , 162 and the orienting rod 11 . When torsional forces act upon the orienting rod 11 , the orienting rod 11 ceases to rotate or rotates at a lower rotational speed than the turning rod 167 . Prior to the inclusion of the ratchet assembly, these torsional forces would act severely enough on the drilling rod assembly 9 to shear the orienting rod 11 , thus destroying the ability to ascertain the true orientation of a cut core sample. With the ratchet assembly, the torsional forces act on the plate 160 , causing the plate teeth 161 to slip relative to the teeth 164 of the second body 162 . This allows for a differential in the turning speeds of the orienting rod 11 and the turning rod 167 , thus suppressing the breakage of the orienting rod 11 .
[0027] While the foregoing has described in detail preferred embodiments known at the time, it should be readily understood that the invention is not limited to the disclosed embodiments. The invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. For example, while three scribing means 13 a - c are shown and described, it should be appreciated that two or more than three such scribing means can be grouped closely together on one side and opposite from another such scribing means within a core taking apparatus. Accordingly, the invention is not limited to the embodiment specifically described but is only limited by the scope of the appended claims. | A device for preserving the orientation of a core is described. A core barrel is attached to a rotatable orienting rod. A plurality of projections are located on an inner surface of the core barrel. Three projections are grouped together and opposite from a fourth projection. A ratchet assembly is included at an end of the rotatable orienting rod opposite from the core barrel. The ratchet assembly includes a first body, to which the rotatable orienting rod is attached, a plate, a second body, and a biasing mechanism. A turning rod is mounted on the plate, which is located between the two bodies. The plate and the second body each have teeth which intermesh, but which slip if a clog in the core barrel inhibits rotation of the rotatable orienting rod. | 4 |
RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/114,578, filed on or about Apr. 2, 2002 now U.S. Pat. No. 6,606,358, which is a continuation of application Ser. No. 09/605,133, filed on or about Jun. 27, 2000, now U.S. Pat. No. 6,430,238, which is a continuation of application Ser. No. 09/049,830, filed on or about Mar. 27, 1998, now U.S. Pat. No. 6,125,154, the contents of each of are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to servo pulse detection and position error signal demodulation for information storage/retrieval devices, such as magnetic disk drives.
BACKGROUND OF THE INVENTION
Servo detection and demodulation are commonly used in disk/tape drives in which information is stored on multiple tracks on a storage medium. In order to increase the storage density of these devices, the tracks are placed closer together, resulting in a tighter tolerance specification for positioning the read/write head over the surface of the medium. In a magnetic disk drive, servo data are usually written on the storage medium once during the manufacture of the drive. The servo patterns typically contain gray-coded track/sector identification (ID) information as well as positioning error information. When read by a magnetic pickup head, these data patterns present themselves as analog waveforms corrupted by electronics and media noise. The servo pulse detection circuit converts the analog pulses in the gray-code ID field of the servo pattern into clearly distinguishable digital pulses so that the information can be further processed using simple logic circuits. A servo error demodulator circuit determines the positioning error of the head relative to the center of the nearest track the head is located on. Conventional servo pulse detectors are typically designed using analog peak detectors similar to the conventional peak detector circuit used for the main data channel in magnetic disk. Integrating the servo channel and the main data channel on a monolithic silicon chip is relatively simple and has been a cost effective solution. However, with the advent of digital maximum likelihood channels which improves the recording density of magnetic disk drives, the main data channel circuitry becomes predominantly digital. Implementing the servo channel using digital circuitry thus become more desirable to ease the integration of the servo and main data channels.
It is desirable to provide a digital circuit technique for servo pulse detection and servo error demodulation which are compatible with the circuit techniques used in a digital read channels.
SUMMARY OF THE INVENTION
Several difficulties arise when performing digital pulse peak detection in digital domain. The main problem is that discrete time signal processing introduces a time quantization effect that can be reduced only through using a higher system sampling rate. The present invention uses both system clock edges to perform digital pulse peak detection to mitigate the inaccuracies caused by discrete time signal processing.
The present invention includes an area-based automatic gain control loop. This provides a very desirable feature of generating position error signals that are already normalized and independent of the incoming input frequency spectra when, for example, the head moves across multiple recording zones.
The present invention also includes a differentiating band-pass filter for servo burst filtering, independent of the equalizing filter used for servo pulse detection. The differentiation characteristic of this filter enables the accuracy of position error signal (PES) demodulation to be independent of the offsets in the analog front end circuits of the channel. The bandpass characteristic of the filter removes much of the noise in the PES bursts, resulting in a higher accuracy in PES demodulation in the presence of wide band input noise.
In the following description, we will use the term “digital data” or “digital vector” to imply a group of related digital signal bits (e.g., a digital bus, or a group of related digital buses) that represents an analog signal in digital domain. The term “digital signal” refers to a single bit digital line.
The input to the servo channel of the present invention is a first analog signal read back from the servo data field of a storage media. The servo data field contains a synchronization field, followed by a gray-code ID field and then a multiple of position error burst fields.
The servo channel also includes a programmable gain amplifier (PGA) to amplify the first analog signal to a second analog signal. An analog filter filters the second analog signal to provide a third analog signal. An analog to digital converter (ADC) digitizes the third analog signal to provide a first digital data. A digital differentiator receives a first digital data and provides, in response thereto, a second digital data. A digital up-sampler processes the second digital data to provide a plurality of digital data, each of which is an interpolated version of the second digital data at a different sampling delay. The digital up-sampler provides a higher equivalent sampling rate of the system without actually operating any circuits at a higher clock rate. An absolute value function circuit rectifies the interpolated digital data and sums them together to provide a fourth digital data. A digital area-based gain control unit (AGU) compares the signal level of the fourth digital data against a target value and generates a fifth digital data which controls the gain setting of the PGA. The AGU adjusts the gain of the PGA until the signal level of the fourth digital data achieves a certain target value. The signal path starting from the first analog signal to the fifth digital data forms an automatic gain control loop. This loop is active during the synchronization field of the servo loop. The gain of the PGA is frozen after the synchronization field.
A programmable coefficient digital FIR filter equalizes the first digital data to provide a sixth digital data. A digital peak detector processes the sixth digital data to provide a servo pulse signal and an optional pulse polarity signal. The FIR filter and the digital peak detector is used to provide a cleanly detected gray-code ID pulses for further servo ID detection by external control logic.
A digital area integrator integrates the fourth digital data to provide a plurality of digital outputs representing the servo position error signal (digital PES). This digital PES data can be read directly by an external servo DSP unit outside of this invention. An optional digital to analog converter (DAC) array converts the digital PES data back to analog PES signals to provide compatibility for back end servo processor systems that expect to receive the demodulated PES signals in analog form.
The digital area gain control unit comprises a first integrator which substantially integrates every half cycle of the servo sync field section of the fourth digital data. This is achieved by making the half cycle period in the servo sync-field substantially equal to an integer multiple of the sampling clock period. The half cycle integrated value is compared against a target level and a difference value is generated and referred to as the gain error data. The gain error data is further accumulated by a second integrator to produce the gain control data for the PGA. The second integrator includes a saturator to prevent overflow or underflow of the gain control data.
The digital peak detector comprises a differentiator, a threshold detector and a zero-crossing detector. The differentiator converts peaks in the incoming data into zero-crossings in its outgoing data. The threshold detector produces a valid-positive-peak data indicator any time the incoming signal is greater than a certain positive threshold, and a valid negative peak indicator when the signal is below a certain negative threshold. The zero-crossing detector produces a negative-servo-pulse output and a positive-servo-pulse output. The negative servo-pulse is asserted when a positive transitioned zero crossing is detected and the valid-negative-pulse output is asserted. The positive servo-pulse is asserted when the negative transitioned zero crossing is detected and the valid-positive-pulse output is asserted. An optional OR gate combines the positive servo-pulse and the negative servo-pulse signals together to provide a composite servo-pulse output. An optional set-reset flip-flop has its set and reset inputs controlled by the negative-servo-pulse and the positive-servo-pulse to provide an output indicating the original polarity of the servo pulse for the composite servo-pulse output. A multiplexer selects either the separated negative/positive servo pulse signals, or the composite and polarity signals as the output of the servo pulse detector.
The digital area integrator for PES demodulation integrates the PES burst field section of the fourth digital data each time the burst gate control signal is asserted. The integration length is the smaller of the burst gate assertion time period and a programmed burst count value. The integrated value is sequentially loaded into a plurality of registers upon every deassertion of the burst gate signal. Under normal operation, the burst gate assertion time period in number of the servo system clock preferably is longer than the programmed burst count value. The user may also program the burst count value so that the total integration time substantially covers an integral multiple of the servo PES burst cycles for improved PES demodulation accuracy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a digital servo channel in accordance with the present invention.
FIG. 2 is a graphical view illustrating a typical servo read back waveform from a conventional magnetic disk drive.
FIG. 3 is a block diagram illustrating a digital area-based gain control circuit of FIG. 1 .
FIG. 3 a is a block diagram illustrating an exemplary gain-error generator of FIG. 3 .
FIG. 3 b is a block diagram illustrating an exemplary gain-integrator of FIG. 3 .
FIG. 4 is a graph illustrating the desired magnitude transfer function for the differentiating band-pass filter of FIG. 1 .
FIG. 5 illustrates an implementation of the interpolator array of FIG. 1 for m=2, which is the preferred embodiment of the present invention.
FIG. 6 is a block diagram of the absolute value summer circuit of FIG. 1 .
FIG. 7 is the block diagram illustrating the digital peak detector of FIG. 1 in accordance with the present invention.
FIG. 8 is a timing diagram illustrating the internal timing of the peak detector circuit of FIG. 7 .
FIG. 9 is a block diagram illustrating the digital area integrator of FIG. 1 in accordance with the present invention.
FIG. 9 a is an illustration of the internal timing of the digital area integrator of FIG. 9 .
DETAILED DESCRIPTION
Referring to FIG. 1 , there is shown a schematic block diagram illustrating a digital servo channel 100 in accordance with the present invention. The digital servo channel 100 includes an automatic gain controller 101 , a digital position error demodulator 103 , and a servo gray code pulse detector 105 .
The automatic gain controller 101 includes a programmable gain amplifier (PGA) 102 , an analog filter 104 , an analog-to-digital converter (ADC) 106 , a digital differentiator 108 , an interpolator array 114 , an absolute value summer circuit 116 , and a digital gain control circuit 118 . An analog input signal 131 from a transducer (not shown) is applied to an input of the programmable gain amplifier (PGA) 102 , which provides an amplified analog signal 133 to the input of the analog filter 104 in response to the input signal 131 and to a gain control vector 145 . The analog filter 104 provides a filtered analog signal 135 to the input of an analog-to-digital converter (ADC) 106 . In some channels 100 , the analog filter 104 need not be present, and, in these channels, the analog signals 133 and 135 are identical. The ADC 106 digitizes the filtered analog signal 135 to provide a raw digital vector 137 , which is a digital representation of the analog signal 135 , to the digital differentiator 108 . The digital differentiator 108 preferably has the transfer function shown in FIG. 4 . In response to the raw digital vector 137 , the digital differentiator provides a digital differentiated filtered vector 139 to the interpolator array 114 . The interpolator array 114 processes the digital vector 139 to provide a plurality of interpolated digital vectors 141 - 1 through 141 - m . The digital vectors 141 - 1 through 141 - m form a close representation of the digital vector 139 at different sampling times. Each interpolated digital vector 141 is indicative of an upsampled value representative of the differentiated filter signal 139 at a different sample time. One of the interpolated digital vectors 141 - 1 through 141 - m may be a delayed version of the digital vector 139 to simplify the hardware requirements of the interpolator array 114 .
The absolute value summer circuit 116 rectifies the interpolated digital vectors 141 - 1 through 141 - m and arithmetically sums them together to provide a digital rectified vector 143 , which is indicative of the rectification and summing of the absolute values of the interpolated digital vectors 141 - 1 through 141 - m . The digital rectified vector 143 may be, for example, indicative of the half cycle area of the sync field burst when the channel 100 is processing the servo sync field region. In response to the digital rectified vector 143 , the digital gain control circuit 118 provides the digital gain control vector 145 to control the gain setting of the PGA 102 . When the servo channel 100 is in a gain acquisition mode, the digital gain control vector 145 is adjusted until the magnitude of the digital rectified vector 143 reaches a predetermined level.
The servo gray code pulse detector 105 includes a programmable coefficient digital finite impulse response (FIR) filter 110 and a digital peak detector 112 . The programmable coefficient digital FIR filter 110 equalizes the raw digital vector 137 to provide a digital vector 151 . The digital peak detector 112 processes the digital vector 151 to provide digital signals 153 and 155 . The digital peak detector 112 can be configured so that the digital signals 153 and 155 either include the servo-pulse signal and the servo pulse-polarity signal, respectively, or include the positive servo-pulse signal and the negative servo-pulse signal, respectively.
The digital position error demodulator 103 includes a digital area integrator 120 and a digital-to-analog converter (DAC) array 122 . The digital area integrator 120 integrates the digital rectified vector 143 to generate a plurality of digital vectors 147 - 1 through 147 - n which represent the servo position error signals (digital PES vectors). The digital to analog converter (DAC) array 122 converts the digital PES vectors into analog PES signals 149 - 1 through 149 - n to provide backward compatibility for back-end systems that receive the demodulated PES signals in analog form. Of course if the back-end system receives digital PES signals, the digital position error demodulator 103 need not include the DAC array 122 .
Referring to FIG. 2 , there is shown a graphical view illustrating an example of a servo read back waveform of a conventional servo patterns used in magnetic disk drives. The servo read-back waveform typically includes a single frequency servo sync-field 201 , a gray-coded servo track/sector ID field 203 , an address mark or gap field 202 separating the sync-field 201 from the ID field 203 , and also includes a plurality of single frequency servo position error burst signals 204 - 1 through 204 - n . The servo sync field 201 provides a training field for a servo channel (not shown) to adjust its gain control loop. During the track/sector ID field, the servo channel converts received analog pulse patterns into an unambiguous train of digital pulse patterns with low error rate for further processing by back-end controller circuits which only handle digital pulses. The gap field or address mark indicates to the back-end controller the start of the ID field. Typically, the digital pulses to be generated during ID field processing are designed to be located at the peaking instances of the input analog waveform. Thus, a peak detector is commonly used to perform servo pulse detection. Other servo schemes may use the zero crossings of the analog waveform to encode the digital pulse position. In this case, servo pulse detection can still be performed using a peak detector by first differentiating the incoming signal to convert zero-crossings into analog pulse peaks.
The head tracking information is derived from the servo PES fields. Typically, several servo burst fields are written on the disk in a staggered fashion so that the read back amplitude of each one of them will be different and depends on the positioning of the head. A common scheme used in the art is to use four servo PES bursts commonly referred to as the A, B, C and D bursts. By reading the magnitude of burst A, B, C and D, a back-end servo processor can make the correction to guide the head on track. The servo burst demodulator converts the single tone sinusoidal like burst signals from the read back waveform into clean DC signals for representing the magnitude of burst A, B, C and D respectively.
Referring to FIG. 3 , there is shown a schematic block diagram illustrating the digital area-based gain control circuit 118 . The digital gain control circuit 118 includes an N-cycle integrator 302 , a gain-error generator 304 , and a gain integrator 306 . The N-cycle integrator 302 substantially integrates a half cycle of the digital rectified signal 143 to generate an area signal 331 . This can be easily achieved by making the half cycle period substantially equal to an integer multiple of the sampling clock period. The half cycle integrated value represents the area of a half cycle in the servo sync-field. The gain-error generator 304 compares the half cycle area value to a predetermined value and generates a gain error signal 333 , which is accumulated by the gain integrator 306 during sync-field acquisition to produce the digital gain control vector 145 .
Referring to FIG. 3 a , there is shown a block diagram illustrating an exemplary gain-error generator 304 , which includes a saturator 308 , a subtractor 310 , and a multiplier 312 . The subtractor 310 subtracts the half cycle area signal 331 from a pre-selected target value 339 to produce a raw gain error signal 335 . The saturator 308 is a minimum-maximum limiter which processes the raw gain error signal 335 to generate a modified gain error signal 337 having a value that is within a range less than the range of the values of the raw gain error signal 335 . The multiplier 312 multiplies the modified gain error signal 337 with a gain-error scaling value 341 to generate the final gain error signal 333 . The gain-error scaling value 341 is programmed or hardwired to achieve the desired gain acquisition tracking bandwidth. Pipeline delays may be added to the gain-error generator 304 to increase the speed of the gain-error generator 304 .
Referring to FIG. 3 b , there is shown a block diagram illustrating an exemplary gain integrator 306 of FIG. 3 . The gain integrator 306 includes an adder 314 , a saturator 316 , and a register 318 . During normal accumulation, the adder 314 adds the gain error signal 333 to the digital gain control signal 145 to produce a next gain control signal 351 . The saturator 316 limits the range of the next gain control signal 351 to generate a range-limited gain control signal 353 . The register 318 receives the range-limited gain control signal 353 and transfers out the digital gain control signal 145 in the next accumulator update cycle. The saturator 316 prevents overflow and underflow of the arithmetic operation involved in integration.
Referring to FIG. 4 , there is shown a graph illustrating the magnitude transfer function for the differentiating band-pass filter (DIFF) 108 . Since the sync-field as well as the PES burst fields are single tone frequency pattern, it is advantageous to use a bandpass filter to pass the desired burst signals and reject other noise components as much as possible. Towards this end, a differentiating bandpass filter may be used because of its extra capability of rejecting DC offset value from the input signal. The desired magnitude transfer function is shown in FIG. 4 The transfer function is zero at DC, peaks at around the frequency of the sync/PES field fundamental frequency, and drops to a low value after twice the peaking frequency. The filter simultaneously rejects the DC component as well as the high frequency noise component in the digitized signal 139 . The filter may be, for example, an FIR filter. For a simplified implementation, the filter may be an FIR filter with fixed binary coefficients of simple powers of two. For a servo channel operating at a sampling clock of approximately 8 times the burst frequency, an FIR filter with coefficients having relative values of 1,2,1,0,−1,−2,−1 may be used.
Referring to FIG. 5 , there is shown a block diagram illustrating an exemplary interpolator array 114 . For clarity, an interpolator array 114 with m=2 is shown. The interpolator array 114 includes a delay/buffer 402 , a delay circuit 404 , and an adder 406 . General signal interpolation can be performed using FIR filters of appropriate coefficients and is well known in the art. For a simple hardware implementation, the delay/buffer 402 provides the first interpolated value 141 - 1 which equals a delayed/buffered value of the digital vector 139 . The delay circuit 404 provides a delayed digital vector 139 to the adder 406 , which adds the delayed vector to the digital vector 139 to generate the second interpolated value 141 - 2 . The second interpolated value 141 - 2 is an equally weighted average of consecutive sample points. The average may be generated by an FIR filter with filter coefficients of (0.5, 0.5), which is a linear interpolation scheme. A higher level of interpolation with m>2 is achieved with linear interpolation with general coefficients of (c, 1−c). Higher order interpolation with more FIR coefficients may be used to improve the interpolation result.
Referring to FIG. 6 , there is shown a block diagram illustrating the absolute value summer circuit 116 , which includes absolute value generators 802 - 1 through 802 - m , and a summer 804 . The absolute value generators 802 - 1 through 802 - m generate respective absolute value signals 831 - 1 through 831 - m , which are the absolute value of respective interpolated digital vectors 141 - 1 through 141 - m provided by the interpolator array 114 . The summer 804 sums the absolute value signals 831 - 1 through 831 - m together to produce the digital rectified vector 143 . A number m of interpolated digital vectors 141 greater than 1 reduces the variation in the absolute-area integration values due to uncertain phase relationship between the incoming analog input signal 131 and a digital system clock (not shown).
Referring to FIG. 7 , there is shown a block diagram illustrating the digital peak detector 112 . Referring to FIG. 8 , there is shown a timing diagram illustrating the timing of the digital peak detector 112 . The digital peak detector 112 includes a late peak detector 702 , a threshold detector 704 , a zero-crossing detector 706 , a differentiator 708 , delay circuits 710 , 712 , 714 , 716 , and 718 , an invertor 720 , AND gates 722 , 724 , 726 , 728 , 730 , and 732 , and OR gates 734 and 736 . The digital peak detector 112 performs signal peak detection in a digital domain as opposed to an analog domain. The output signals of the digital peak detector 112 are pulses similar to those of an analog peak detector. Because the digital peak detector 112 operates at a finite clock operating frequency, the digital output pulses occur on the sampling clock edges. This introduces time quantization effects, reducing the accuracy of recovered peak position compared to an analog peak detector. To mitigate the time quantization effect, the peak detector circuit 112 uses both the rising and falling edges (i.e., both clock phases) of the system sampling clock to generate the output pulses. This effectively doubles the sampling rate of the system to improve the precision in the recovery of the peak positions in the incoming signal.
The threshold detector 704 produces QPP and QNP signals. The QPP signal is asserted any time that the input digital vector 151 exceeds a programmed positive threshold PTHR. Similarly, the QNP signal is asserted any time the input digital vector 151 is below a programmed negative threshold NTHR. The QNP and QPP signals are used to qualify only peaks that exceeds the specified threshold NTHR and PTHR, respectively, to reject unwanted peaks around the base-line of the input digital vector 151 . A peak in the input digital vector 151 is typically detected by detecting a zero crossing in the input digital vector 151 . This is typically done by first differentiating the input digital vector 151 so that peak locations become zero-crossing locations. The zero-crossing detector 706 detects zero-crossing for both positively going and negatively going signal transitions. The state equations of the digital peak detector 112 are as follows:
The state equations for the threshold detector 704 are:
QNP[n]=X[n]<*NTHR (1)
QPP[n]=X[n]>*PTHR (2)
The state equations for the differentiator 708 are:
Z[n]=X[n]−X[n− 1] (3)
The state equations for the zero-crossing detector 706 are either:
equations (4a) and (5a)
PX[n]= ( Z[n]>= 0) AND ( Z[n− 1]<0) (4a)
NX[n]= ( Z[n]<= 0) AND ( Z[n− 1]>0) (5a)
or equations (4b) and (5b)
PX[n]= ( Z[n]> 0) AND ( Z[n− 1]<=0) (4b)
NX[n]= ( Z[n]< 0) AND ( Z[n− 1]>=0) (5b)
The state equations for the valid/qualified zero-crossing determined by the AND gates 722 and 724 are:
QNX[n]=PX[n] AND QNP[n− 1] (6)
QPX[n]=NX[n] AND QPP[n− 1] (7)
where in equations (1) through (7), 1. the operator, “<*” can be either less-than “<” or less-than-or-equal-to “<=”; 2. the operator “>*” can be either greater-than “>” or greater-than-or-equal-to “>=”; 3. X[n] is the incoming input vector 151 from the FIR filter 110 ; 4. Z[n] is a difference input vector, 5. PX[n] indicates the occurrences of all negative peaks of X[n] or all positive going zero-crossings of Z[n]; 6. NX[n] indicates the occurrences of all positive peaks of X[n] or all negative going zero-crossings of Z[n]; 7. QNX[n] indicates the presence of a positive peak in X[n] that exceeds the specified positive threshold PTHR; 8. QPX[n] indicates the presence of a peak in X[n] that exceeds the specified negative threshold NTHR.
The state equations (1) through (7) provide a simple means of implementing the digital peak detector 112 . The digital peak detector 112 operates on the system sampling clock. Hence, the QNX signal changes value only after the triggering clock edge. To reduce the time quantization effect, the other clock phase of the system clock is also utilized. To do this, the pulse peak position is further determined to occur either early in the clock cycles or late in the clock cycles. The following state equations determine the position of the pulse peak:
The state equations for the early/late peak location detector 702 and the inverter 720 are:
Late[n]= ( X[n+ 1 ]>*X[n− 1]) AND ( X[n]>* 0)
OR ( X[n+ 1 ]<*X[n− 1]) AND ( X[n]<* 0) (8)
Early[n]=NOT Late[n] (9)
The state equations for the pulse shifting of the AND gates 726 , 728 , 730 , and 732 , and the OR gates 734 and 736 are:
NX — E[n+ 0.5 ]=Early[n− 1 ] AND QNX[n] (10)
PX — E[n+ 0.5 ]=Early[n− 1 ] AND QPX[n] (11)
NX — L[n+ 1 ]=Late[n− 1 ] AND QNX[n] (12)
PX — L[n+ 1 ]=Late[n− 1 ] AND QPX[n] (13)
NX=NX — E[n+ 0.5 ] OR NX — L[n+ 1] (14)
PX=PX — E[n+ 0.5 ] OR PX — L[n+ 1] (15)
where in equations (8) through (15), 1. the 0.5 in NX_E[n+0.5] and PX_E[n+0.5] indicates that both signals are latched on the second phase of the system clock. 2. the 1 in NX_L[n+1] and PX_[n+1] indicates that both signals are latched on the main (first) phase of the system clock. 3. NX is the final positive pulse peak output of the peak detector 112 . 4. PX is the final negative pulse peak output of the peak detector 112 .
The state equations (8) through (15) shift the output pulses by a half clock period relative to the sample point depending on whether the actual signal peak would have occurred early or late relative to the digital peak sample point, as illustrated in FIG. 8 . In this case, if the actual peak would have occurred after the digital peak sample point X 2 of FIG. 8 , the output pulse lines up with the system clock and is sent out on the next system clock cycle. If the actual peak position would have occurred before the digital sample peak position, the output pulse is latched earlier by the second phase of the system clock.
To obtain the more common servo output format of a composite pulse output (occurrence of either positive or negative peaks) and peak polarity output, the digital peak detector 112 may include a simple circuit (not shown) comprising an OR gate and an RS flip-flop. The additional OR gate provides the composite pulse output as the OR of the NX and PX signals. The output of the RS flip-flop provides the pulse polarity output. The Reset and Set inputs of the RS flip-flop are separately connected to the NX and PX signals.
Referring to FIG. 9 , there is shown a schematic block diagram illustrating the digital area integrator 120 , which includes a burst integrator 902 , a sequencer 910 , and a plurality of PES holding registers 912 - 1 through 912 - n . The digital area integrator 120 demodulates the digital rectified vector 143 to generate the servo position error vectors 147 . The sequencer 910 generates a reset signal 914 and a plurality of load signals 916 - 1 through 916 - n in response to a servo gate (BCNT) signal 918 and a burst gate (BGATE) signal 920 .
The burst integrator 902 includes an adder 904 , an AND gate 906 , and an accumulator register 908 . The burst integrator 902 integrates the incoming rectified signal 143 when the reset signal 914 is deasserted, and resets the accumulation register 908 when the reset signal 914 is asserted. At the end of every integration sequence, the sequencer 910 simultaneously asserts one of the plurality of load signals 916 - 1 through 916 - n , which enables loading of the value at the output of the accumulator register 908 before it is reset. The PES holding registers 912 - 1 through 912 - n are sequentially loaded with the demodulated PES values of the corresponding servo burst field. The output of the registers 912 - 1 through 912 - n provide the respective digital vectors 147 - 1 through 147 - n , which may be read directly by a servo digital signal processing controller (not shown) or they can be converted in analog signals using the digital to analog converters 122 for backward compatibility to older servo systems that receive the demodulated signals in analog form.
Referring to FIG. 9 a , there is shown a timing diagram illustrating the timing of integrate/load cycle of the PES signals by sequencer 910 . The sequencer 910 is enabled when the servo gate signal 918 is asserted. The sequencer 910 generates a synchronized integrate/reset sequence on the reset line 914 in response to the burst gate signal 920 . The integrate cycle lasts for a programmed number of system clock cycles. At the end of the first integration cycle for the first PES burst field, the integrate cycle is terminated, and the load signal 916 - 1 is asserted to allow loading of the integrated value of the burst integrator 902 into the first PES holding register 912 - 1 . Subsequent burst gate assertion/deassertion cycles enable more integration cycles, but the sequencer 910 directly loads the integrated values into other PES holding registers 912 - 2 through 912 - n by sequential asserting the load signals 916 - 2 through 916 - n. | A servo channel digitally processes the data read from a magnetic media. The channel uses both edges of a system clock to detect peaks and generates position error systems by an area-based automatic gear control loop. By altering the sample delay, the channel digitally, up-samples at higher rates without requiring a higher system clock. | 7 |
[0001] This application claims priority to U.S. Provisional Application No. 61/119,173 which was filed on 2 Dec. 2008.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to collapsible crates and more particularly to a collapsible crate with retractable support members for supporting another container thereon.
[0003] Collapsible crates are well known. Four walls are each connected via a hinge to a base and are selectively movable about the hinge between an upright (or use) position, in which the wall is generally perpendicular to the base, and a collapsed position onto the base. Various latch mechanisms have been provided to connect adjacent walls at the corner to selectively lock the crate in the use position.
[0004] Some collapsible crates also include retractable supports so that another container can be supported thereon. One such crate includes end walls, each of which have a support that is partially supported on the adjacent walls when in the support position. However, in some of the designs, the support does not extend far enough into the mouth of the container, away from the end wall. As a result, it is difficult to reliably stack the other container onto the supports without the other container slipping down between the supports. It would be desirable for the supports to extend further into the container, without interfering with the goods in the container below the supports, and such that the supports are still able to be fully retracted out of the interior of the container.
SUMMARY OF THE INVENTION
[0005] The present application provides a collapsible container including a base, a pair of opposed side walls, and a pair of opposed end walls which are transverse to the side walls. The side and end walls are pivotably connected to the base between an upright position, generally perpendicular to the base, and a collapsed position on the base. The end wall includes a support which is pivotably and slidably mounted thereto. The support is movable between a retracted position, received substantially within the end wall, and a support position extending into the container. When the side wall and the end wall are in the upright position, the support may be urged toward the support position by an optional arm extending from the side wall. Further, the support is pivotably mounted to the end wall about a movable pivot axis. Particularly, the pivot axis slides closer to the upper edge of the end wall when the support is in the support position than when the support is in the retracted position. Thus, the support can be fully retracted within the end wall and allow the support to extend far enough into the container so that it can be used to reliably support another container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0007] FIG. 1 is a perspective view of the container of the present application in an upright, assembled position;
[0008] FIG. 2 is a perspective view of the container of the present application in a collapsed position;
[0009] FIG. 3 is a perspective view of a quarter of the interior the collapsible container of FIG. 1 ;
[0010] FIG. 4 is an exterior view of the corner of the collapsible container of FIG. 3 ;
[0011] FIG. 5 is another view of the collapsible container of FIG. 3 , showing in detail the support in the support position;
[0012] FIG. 6 is a bottom perspective view of the interior corner of FIG. 3 ;
[0013] FIG. 7 is another view of the collapsible container of FIG. 3 , showing the support in the retracted position;
[0014] FIG. 8 is a section view through the side wall showing the arm of the side wall in an unbiased (or undeflected) state with the support in the support position;
[0015] FIG. 9 is a section view through the side wall showing the arm of the side wall in a deflected state with the support in between the support position and the retracted position;
[0016] FIG. 10 is a section view through the side wall showing the arm in a deflected and elastically deformed state with the support in the retracted position;
[0017] FIG. 11 is an exterior view of a corner of the collapsible container of FIG. 1 supporting a second container;
[0018] FIG. 12 is another view of the collapsible container of FIG. 1 , showing in detail the support in the support position with a second container being supported on the support;
[0019] FIG. 13 is a perspective view of another embodiment of the support of the present application with the support in the support position; and
[0020] FIG. 14 is a perspective view of the embodiment of FIG. 13 showing the support in the retracted position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] FIG. 1 is a perspective view of the collapsible container 10 in an upright position. The container 10 includes a base 12 , upstanding side walls 14 (or long walls) and upstanding end walls 18 (or short walls). The side walls 14 and end walls 18 are pivotably connected along long and short edges of the base 12 , respectively.
[0022] FIG. 2 portrays the collapsible container 10 in the collapsed position. The end walls 18 are collapsed onto the base 12 , and the side walls 14 are collapsed onto the end walls 18 . By collapsing the container 10 in this manner, the volume of the container 10 is reduced and the container 10 can be easily stored.
[0023] FIG. 3 is a perspective view of a quarter of the container 10 . The remainder of the container 10 is symmetric. The container 10 is shown in the upright (or assembled) position. Each end wall 18 has a support 20 . The support 20 is pivotably and slidably mounted on the end wall 18 and movable between a retracted position and a support position. The support 20 is shown in FIG. 3 in support position, where it projects into the interior of the container 10 where it can support another container stacked thereon. The supports 20 project into arcuate channels 22 formed in each side wall 14 . The ends of the supports 20 move in the arcuate channels 22 as the end walls 18 are collapsed onto the base 12 .
[0024] FIG. 4 is an exterior view of the corner of the container 10 of FIG. 3 .
[0025] FIG. 5 is an enlarged view of the interior corner of the container 10 of FIG. 3 . The side wall 14 includes an integrally molded deformable arm 40 (or some other deformable structure) that contacts an outer surface of the support 20 . When the side wall 14 and end wall 18 are in the assembled, upright position as shown, the arm 40 urges the support 20 away from the end wall 18 to the support position.
[0026] FIG. 6 shows a bottom perspective view of the interior corner of FIG. 3 . The end wall 18 includes a plurality of openings 24 formed in a plurality of brackets 26 . The support 20 includes a plurality of arms 28 (one shown in this view), each having a hinge pin 30 formed at a lower end thereof. The hinge pins 30 are received in the brackets 26 and are captured in the openings 24 of the brackets 26 . The hinge pins 30 are pivotable and slidable within the openings 24 in the brackets 26 . The hinge pins 30 define a movable axis about which the support 20 pivots. The hinge pins 30 slide to the upper end of the openings 24 when the support 20 is in the support position 20 . The arms 28 extend at an angle inwardly and upwardly from the hinge pins 30 , such that the support 20 extends further into the interior of the container 10 than the supports in some known containers. The end of the support 20 includes a tab 32 projected downwardly behind a rail 34 adjacent the channel 22 . The tab 32 interlocks with the rail 34 to prevent the side wall 14 from deflecting outward which could otherwise permit the support 20 to slip off of the side wall 14 when a load is placed on the support 20 .
[0027] FIG. 7 illustrates the support 20 moved to the retracted position within the end wall 18 . The side wall 14 includes an upper rib 50 providing an upper contact surface that contacts the support 20 as the support 20 is moved toward the retracted position. As the support 20 is moved toward the retracted position, the arm 28 is pivoted outwardly and the support 20 contacts the upper rib 50 , which causes the hinge pin 30 to slide downward within the vertically elongated openings 24 . Also, as the support 20 moves toward the retracted position, the arm 40 is deflected outwardly. The arm 40 continues to urge the support 20 toward the support position, so the support 20 will return to the support position automatically upon release. Note that when the end wall 18 is collapsed onto the base, the support 20 is no longer biased toward the support position.
[0028] FIG. 8 is a section view through the side wall 14 toward the interior of the container 10 . When the support 20 is in the support position, the arm 40 is in contact with the support 20 , but in an undeflected or substantially undeflected, undeformed state. Referring to FIG. 9 , as the support 20 is pushed into the retracted position, the support 20 contacts the upper rib 50 of the side wall 14 . This forces the support 20 to translate downward (i.e. the hinge pin 30 slides down within the opening 24 ( FIG. 7 )). As the support 20 is pushed toward the retracted position, the arm 40 is deflected and elastically deformed outwardly until the support 20 is received in the end wall 18 in the retracted position, as shown in FIG. 10 .
[0029] As shown in FIGS. 11 and 12 , when the supports 20 are in the support position, a second container 200 can be supported on the supports 20 . As shown in FIG. 12 , the support 20 extends further into the interior of the container 10 than some of the supports in the known containers because the support 20 is at the end of a longer, angled arm 28 that pivots and slides relative to the end wall 18 as the support 20 moves to the support position.
[0030] FIGS. 13 and 14 illustrate an alternate container 110 . The container 110 is substantially similar to the container 10 of FIGS. 1-12 , and corresponding parts are referenced with the same reference number, preappended with the numeral “1.” The container 110 includes supports 120 pivotably and slidably mounted to the end walls 118 . The end wall 118 includes a plurality of openings 124 formed in a plurality of brackets 126 . The support 120 includes a plurality of arms 128 (one shown in this view), each having a hinge pin 130 formed at a lower end thereof. The hinge pins 130 are received in the brackets 126 and are captured in the openings 124 of the brackets 126 . The hinge pins 130 are pivotable and slidable within the openings 124 in the brackets 126 . The hinge pins 130 define a movable axis about which the support 120 pivots. The hinge pins 130 slide to the upper end of the openings 124 when the support 120 is in the support position 120 . The arms 128 extend at an angle inwardly and upwardly from the hinge pins 130 , such that the support 120 extends further into the interior of the container 110 than the supports in some known containers. Each support 120 further includes one or more limit arms 144 projecting outwardly and downwardly therefrom. A stop 146 projects outwardly from each limit arm 144 . When the support 120 is pivoted to the support position, as shown, the stop 146 contacts a corresponding stop 148 projecting inwardly from the end wall 118 . The interference between the stops 146 , 148 prevents the support 120 from over rotating inwardly when the support 120 is not supported on the side wall 114 (i.e., while the end wall 118 is being pivoted toward the collapsed position on the base). FIG. 14 illustrates the support 120 in the retracted position, where the stop 146 on the arm 144 of the support 120 is pivoted away from the stop 148 on the end wall 118 .
[0031] In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | A collapsible container is provided which includes a base, a pair of opposed side walls, and a pair of opposed end walls which are transverse to the side walls. The side and end walls are pivotably connected to the base between an upright position generally perpendicular to the base and a collapsed position on the base. A support is pivotably and slidably mounted to each of the end walls. The support is configured to extend into the container and to fully retract within the end wall. The support extends far enough into the container to reliably support another container thereon. | 1 |
[0001] This application is a continuation application claiming priority to Ser. No. 11/179,405 filed Jul. 12, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates generally to computer systems, and more specifically to a program tool to determine what to do when a software installation on a computer is not covered under an existing software license.
BACKGROUND OF THE INVENTION
[0003] Typically, software is licensed not sold. The license includes conditions and restrictions such as (a) a geographic location where (an unlimited number of copies of) the software can be installed, (b) a specific computer CPU serial number in which (an unlimited number of copies of) the software can be installed, (c) a total number of copies which the licensee can install in one or more computers located anywhere, (d) a type of computer (such as production, development, etc.) on which the software can be used, and (e) a maximum size computer (typically expressed in processing power) in which the software can be installed. Often times, one company has multiple licenses that authorize installation of the same type of software, and many copies of the software are installed on different computers of the company. It has proven difficult for many companies to effectively track their licenses and which software copies are licensed when the company is large and has many separate software licenses, software installations and computers. Often times, the result is that one or more software installations are not covered by an existing software license of the company. Usually this is inadvertent, but nevertheless improper. (Often times also, the company has excess software licenses.)
[0004] An IBM Tivoli License Manager program is a known software license management program, and is further described in a document entitled “Introducing IBM Tivoli License Manager” by Manoel, et al. which is available from ibm.com/redbooks. Chapter 2 of this document is hereby incorporated by reference as part of the present disclosure. Using this program, when a license is associated with specific installed software, an administrator enters into a database information about the license. To the extent applicable, this information includes maximum size of the computer processor on which the program can be installed, maximum number of copies of the program that can be installed (on any computer), expiration date, specific CPU serial number on which the program can be installed or executed, and geographic location of the processor for executing (an unlimited number of copies of) the program. The Tivoli License Manager program checks whether each installed software program complies with an existing license by applying the licenses to the installations based on a predetermined and set order of conditions. For example, the Tivoli License Manager may be preprogrammed to apply all licenses having one type of condition to the installations, and then determine which installations are not covered by this type of license. Then, the Tivoli License Manager may be preprogrammed to apply all licenses having another type of condition to the remaining installations, and then determine which installations are not covered by either type of license. Then, the Tivoli License Manager may be preprogrammed to apply all licenses having still another type of condition to the still remaining installations, and then determine which installations are not covered by any of the three license, etc. If the Tivoli License Manager has not associated any remaining installed software with a license after all the licenses have been applied, then it is possible that such remaining installed software is not covered under any existing software license. (If any licenses remain after all the software installations are associated with/covered by any of the previously applied licenses, then the Tivoli License Manager deems the remaining licenses as excessive or unnecessary, and they can be terminated to save the company money.)
[0005] Copending U.S. patent application entitled “System, Method and Program Product To Identify Unutilized or Underutilized Software License”, Ser. No. 11/157,397, filed by J. Marsnik, O. Nalamwar and T. Smalley on Jun. 21, 2005 (IBM Docket END9-2005-0014) discloses an improved program tool for identifying installed software which is not licensed as well as excess or under utilized licenses. According to this patent application, the improved program tool applies the software licenses in various orders to the software installations, where each order is based on a different prioritization of license conditions. For example, in one order, all licenses with a condition on geographic location are applied first, then all licenses with a condition on total number of copies are applied second, then all licenses with a condition on specific CPU are applied third, etc. In another order, all licenses with a condition on total number of copies are applied first, then all licenses with a condition on geographic location are applied second, then all licenses with a condition on specific CPU are applied third, etc. In still another order, all licenses with a condition on specific CPU are applied first, then all licenses with a condition on total number of copies are applied second, then all licenses with a condition on geographic location are applied third, etc. This patent application is hereby incorporated by reference as part of the present disclosure. After all the licenses are applied in the different orders to the software installations, if none of the licenses covers one or more software installations in any of the orders, then that software installation is not licensed. (Also, if less than all the licenses are needed to cover all the software installations in any of the orders, then the remaining licenses are unnecessary and can be terminated to save the company money.)
[0006] While the foregoing techniques are effective in identifying unlicensed software installations, they do not disclose a technique to determine what to do when such unlicensed software installations are identified, other than to simply decommission/delete the unlicensed software installation. This may not be in the best interest of the user/company.
[0007] Accordingly, an object of the present invention is to determine what to do when unlicensed software installations are identified, to serve the interest of the user/company.
SUMMARY
[0008] The present invention resides in a computer system, computer implemented method and computer program product for determining a recommended course of action to resolve an unlicensed software installation of a type of software in a computer of a company. A determination is made as to an amount or level of use of the type of software by the company during a predetermined period of time. A determination is made if the type of software is currently installed on another computer of the company. A determination is made if the software of the unlicensed software installation can be relocated to the other computer of the company and encompassed under another existing license for the other computer.
[0009] In accordance with features of the present invention, recommendations are automatically made based on the foregoing determinations.
[0010] The present invention also resides in a computer system, computer implemented method and computer program product for determining a recommended course of action to resolve an unlicensed software installation of a type of software in a computer of a company. Characteristics of the company's use of the type of software which would permit removal of the type of software from all computers of the company are automatically evaluated. Characteristics of the company's use of the software installation which would permit removal of the software installation are automatically evaluated. Characteristics of the company's use of the type of software which would permit relocation of the software from the unlicensed software installation to another computer of the company at which the software would be licensed are automatically evaluated.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a block diagram of a computer system in which the present invention is incorporated.
[0012] FIG. 2 is a flow chart of a software license resolution program within the computer system of FIG. 1 according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The present invention will now be described in detail with reference to the figures. The present invention is implemented with a programmed computer such as computer 10 illustrated in FIG. 1 . Computer 10 includes a known CPU 12 , operating system 13 , RAM 14 , ROM 16 , disk storage 18 , and TCP/IP card 20 . Computer 10 also includes a software license review program 22 which compares license conditions and scope of a plurality of software licenses for the same type of software to the actual software installations to determine if all of the software installations are licensed (or “compliant”). (Program 22 also determines if any of the software licenses are not needed at all and therefore can be terminated, i.e. other software license(s) cover/license all the software installations. Program 22 also determines if an individual software license can be reduced in scope, i.e. reduced in the number of copies licensed. Either case will reduce the total license fees for the licensee.) Program 22 can be the known IBM Tivoli License Manager program described above (for certain types of single-condition software licenses) or the software license optimizing program disclosed in U.S. patent application entitled “System, Method and Program Product To Identify Unutilized or Underutilized Software License”, Ser. No. 11/157,397, filed by J. Marsnik, O. Nalamwar and T. Smalley on Jun. 21, 2005 (IBM Docket END9-2005-0014), described above (for a wider range of software licenses including those with multiple conditions). As explained above, the IBM Tivoli License Manager program applies the software licenses to the software installations in an order based on the type of condition in each license, and a predetermined order of such conditions. After all the licenses are applied to the software installations, if none of the software licenses covers/license one or more of the software installations, then such one or more software licenses are not licensed. The software license optimizing program of U.S. patent application entitled “System, Method and Program Product To Identify Unutilized or Underutilized Software License”, Ser. 11/157,397, filed by J. Marsnik, O. Nalamwar and T. Smalley on Jun. 21, 2005 (IBM Docket END9-2005-0014) applies the software licenses to the software installations based on the type of condition in each license, and different orders of such conditions in different iterations of the program. After all the licenses are applied in the different orders to the software installations, if none of the licenses covers/licenses one or more software installations in any of the orders, then such one or more software installation are not licensed.
[0014] Computer 10 also includes a software license resolution program 24 according to the present invention. Program 24 determines what to do when a software installation in one of the company's computers is not covered/licensed by an existing software license. As explained in more detail below, program 24 has expert system rules to determine when to (a) decommission/delete this software from all computers of the company, (b) decommission/delete an installation of the software on any computer of the company so that an existing license has sufficient scope (or “room”) to license the remaining software installation(s), (c) move the currently unlicensed software to another computer where it will be properly licensed under an existing license (such as a geographic location license or CPU license), (d) renegotiate an existing license to extend/expand the scope of the existing license to cover the currently unlicensed software installation, or (e) purchase a new license to cover the currently unlicensed software installation. Program 22 and 24 are stored on computer readable storage 18 for execution by CPU 12 via memory.
[0015] FIG. 2 illustrates the functional steps and operation of program 22 and program 24 in more detail. In step 122 , program 22 conducts an inventory of each type of software which is currently installed in computers of a company, for example, the user's company or the user's customer. The inventory identifies each computer (and its serial number) on which the type of software is installed, the geographic location of the computer, and the number of installed copies of the type of software. If there are other conditions or restrictions on usage specified in the associated software licenses (such as listed below), the inventory can identify other, corresponding characteristics of the usage. Program 22 conducts this inventory by querying configuration files and other files for the computers containing this information. Program 22 records the results of the software usage inventory in a table or file 101 (shown in FIG. 1 ). Before, after or concurrent with software installation inventory, the user conducts an inventory of the software licenses for this type of software used by the one company. The inventory identifies the type(s) of usage condition(s) or restriction(s) in each software license. After conducting the inventory, the user populates a table or file 103 (shown in FIG. 1 ) with fields and predetermined key words for the different types of conditions or restrictions. By way of example, a condition or restriction may state the following:
[0000] (a) The type of software can only be used on a specified computer (typically specified by the computer CPU serial number), with no restriction on the number of copies that can be installed on the specified computer or the geographic location of the specified computer. In file 103 , this type of license is referenced by the key word, “CPU Serial #”.
(b) The type of software can only be used at a specified geographic location of the computer CPU, with no restriction on the number of computers at that geographic location on which the type of software can be installed or the number of copies of the software that can be installed at that geographic location. In file 103 , this type of license is referenced by the key word, “Location City XYZ”.
(c) The total number of copies of the type of software that can be used, with no restriction on the number of computer CPUs on which the software can be installed or the geographic location of the computer CPUs on which the software can be installed. In file 103 , this type of license is referenced by the key word, “Number of Copies #”.
(d) The maximum processing power of a computer CPU on which the type of software can be used, with no restriction on the number of copies that can be installed on the computer or the geographic location of the computer.
(e) The business unit which uses software.
(f) The number of Logical Partitions (“LPARS”) in which the software can be used.
(g) The number of actual users of the software program.
(h) The number of computers or server “nodes” on which the software can be installed.
(i) A type of computer (such as production, development, etc.) on which the software can be installed.
After performing the inventory of the software licenses, program 22 records the results of the software usage inventory in file 103 .
[0016] In one example, there are five software licenses applicable to the same type of software for the one company. In this example, each of the software licenses has only one of the following restrictions: (i) computer CPU serial number in which the software can be installed (unlimited number of copies on the computer, unrestricted geographic location of the computer CPU), (ii) geographic location of the computer CPU in which the software can be installed (unlimited number of computers at the geographic location in which the software can be installed, unlimited number of copies that can be installed on the computer(s) at the geographic location), or (iii) total number of copies of the software that can be installed (unlimited number of computer CPUs up to the total number of copies, unrestricted geographic location of the computer CPUs). In this example, license #1 has only the condition of computer CPU serial number, license #2 has only the condition of geographic location of the computer CPU, license #3 has only the condition of total number of copies of the software, license #4 has only the condition of geographic location of the computer CPU, and license #5 has only the condition of the computer CPU serial number. It should be noted that the foregoing example is just one possible example. Program 22 can evaluate other types of software licenses with other types of individual conditions or combinations of conditions (in a single license).
[0017] As described below, in one embodiment of program 22 (as described in Copending U.S. patent application entitled “System, Method and Program Product To Identify Unutilized or Underutilized Software License”, Ser. No. 11/157,397, filed by J. Marsnik, O. Nalamwar and T. Smalley on Jun. 21, 2005 (IBM Docket END9-2005-0014)), program 22 compares the software licenses to the software inventory in different orders of the software license conditions; one or more of the orders will reveal the most excesses, if any, in the software licenses. If there are such excesses, this represents an opportunity to terminate or reduce the scope of the excess software license(s), and thereby, reduce the license fees. Conversely, if none of the existing software licenses covers one or more of the software installations during any order of applying the software licenses, then such one or more software installations are unlicensed (or noncompliant with existing licenses), and program 22 invokes program 24 to determine how to resolve this problem. In some cases, there is no license whatsoever for the subject software installation. In other cases, there is a software license intended for the software installation, but the software installation does not comply with one or more conditions of the intended license. For example, the intended software license may be limited to a CPU of a certain maximum processing power, and the actual software installation may be on a computer with greater processing power. In either case (either no license or an inadequate license), the software installation is considered unlicensed.
[0018] Thus, after program 22 identifies one or more software installations as being unlicensed in step 100 and invokes program 24 , program 24 determines a course of action to satisfy the licensee's needs without violating the copyright laws or breaching an existing software license. In other words, program 24 will determine a course of action that will result in all (remaining) software installations of the company being properly licensed. As explained in more detail below, program 24 will determine the viability and desirability of the following remedies, preferably in the following order: (a) decommission/delete the software from all computers of the company, (b) decommission/delete an installation of this software on another computer of the company so that an existing license has sufficient scope (or “room”) to license the currently unlicensed software installation, (c) move the currently unlicensed software to another computer where it will be properly licensed under an existing license of the company, (d) renegotiate and expand an existing license of the company to extend the existing license to the currently unlicensed software installation, or (e) purchase a new license to cover the currently unlicensed software installation.
[0019] Accordingly, in step 204 , program 24 determines if the currently unlicensed software installation should be decommissioned/deleted from all computers of the company, based on the following expert system rules in a rules data base 201 :
[0000] (a) An administrator previously classified the software installation as “non critical”, and previously recorded this classification in a table 203 , and any one of the following situations applies:
(i) the software has not been used for a past, predetermined time period, such as thirteen months, on any computer of the company. (Each time the software has been used, the operating system 13 records the date of such use in table 203 ;) or
(ii) the software has been used “lightly” for a past, predetermined time period, such as thirteen months, on all computers of the company and an administrator previously recorded in table 203 that comparable software is currently installed on a computer of the company. (Program 24 determines “light” usage by comparing the number of uses recorded in table 203 to a threshold previously recorded by the administrator in table 203 ); or
(iii) the software has been used lightly for a past, predetermined time period, such as thirteen months, on all computers of the company and the usage has been decreasing faster than a predetermined rate (as indicated by the records in table 203 ); or
(iv) an administrator previously made a record in table 203 that the customer intends to discontinue use of this software; or
(v) the currently unlicensed software installation has not been accessed for a past, predetermined time period, such as thirteen months; or
(vi) the software is responsible for a predetermined percentage or more of the licensee's important failures (“business capabilities failures”) in the last year (based on records previously entered by a support person in table 203 ), and is functionally redundant to another installed software product (based on records previously entered by an administrator in table 203 ).
If the company's situation permits the resolution considered in step 204 , then program 24 notifies the administrator of this recommended resolution (decision 206 , yes branch), and that the cost is low, i.e. the labor cost of decommissioning the software from all computers of the company (step 230 ). There is no additional license fee. In addition, if one or more software licenses can be terminated due to the decommissioning of the software based on the recommendation of step 204 , and there is an ongoing cost associated with the one or more software licenses as recorded in file 103 , program will notify the administrator of the potential cost savings.
[0020] If the software installation cannot be decomissioned/deleted from all the computers of the company based on the rules of step 204 (decision 206 , no branch), program 24 determines if the software type of the currently unlicensed software installation can be decommissioned/deleted from another computer of the company to “make room” for the currently unlicensed software installation under an existing license (step 208 ), based on the following rules:
[0000] (b) the software is installed on another computer of the company, the software was substantially underutilized there (based on the records previously entered by operating system 13 in table 203 as to usage of the software and a usage threshold previously entered by the administrator in table 203 representing substantial under utilization), and an existing license would cover the currently unlicensed installation if the software was decommissioned/deleted from this other computer. For example, there may be an existing license that is limited to total number of installed copies or total number of sites where the software is installed, and the license is currently at its limit, and decommissioning of the software at the other computer would make room for currently unlicensed software installation. In such a case, the currently unlicensed software installation can be decommissioned/deleted on this other computer, and the company can rely on the existing license to license the currently unlicensed software installation.
If the company's situation permits the resolution considered in step 208 , then program 24 notifies the administrator of this recommended resolution (decision 210 , yes branch), and that the cost is low, i.e. the labor cost of decommissioning the unlicensed software installation at the other computer (step 230 ). There is no additional license fee.
[0021] If the unlicensed software installation cannot be decomissioned/deleted based on the rules of step 208 (decision 210 , no branch), program 24 determines if the software of the currently unlicensed installation can be relocated to another computer of the company, i.e. installed on another computer of the company under an existing, underutilized license and the currently unlicensed software installation decommissioned/deleted (step 212 ), based on the following rules:
[0000] (c) an existing license of the company permits installation of the software on another computer with sufficient resources—CPU, RAM, etc. (as program 24 determines by query of configuration files of this other computer and comparison to resource data previously entered by the administrator in table 203 indicating resource requirements of the software) to effectively execute the software, without additional charge or with substantially less charge than another, new license of the same type.
If the company's situation permits the resolution considered in step 212 , then program 24 notifies the administrator of this recommended resolution (decision 214 , yes branch), and that the cost is low, i.e. the labor cost of relocating the software from the computer of the unlicensed installation to another computer of the company (step 230 ). There is no additional license fee.
[0022] If the software installation cannot be moved to another computer and licensed under an existing, underutilized license at this other computer based on the rules of step 212 (decision 214 , no branch), program 24 determines if an attempt should be made to renegotiate an existing license of the company for this software to expand it to license the currently unlicensed software installation (step 216 ), based on the following rules:
[0000] (d) The administrator on behalf of the company has previously recorded in table 203 an intent of the company to retain and invest in this type of software. Also, there is an existing license for another installation of this software on another computer or an existing license intended for the current installation (which is inadequate in some respect, such as a limit on processor power or geographic location, for the current installation) which will expire in less than a predetermined time period, such as nine months. In such a case, program 24 will estimate a cost for an expanded license to cover the currently unlicensed installation. Program 24 estimates the cost for licensing the unlicensed software installation based on a fixed, predetermined percentage (such as 25%) of the total license fee for the existing license plus the total license fee for the existing license divided by the number of copies licensed under the existing license.
If the company's situation permits the resolution considered in step 216 , then program 24 notifies the administrator of this recommended resolution (decision 218 , yes branch), and the estimated cost as noted above (step 230 ).
[0023] If an existing software license should not be renegotiated and expanded to license the currently unlicensed software installation based on the rule of step 216 (decision 218 , no branch), program 24 determines if another, new license should be purchased for the currently unlicensed installation (step 220 ), based on the following rules:
[0000] (e) The administrator previously recorded in table 203 that it is critical to the company to keep the currently unlicensed software installation on the same computer. In such a case, program 24 will estimate a cost for the new license for the currently unlicensed software installation. Program 24 estimates this cost for the new license as the same cost for any comparable existing license (based on data in table 103 ). If there is no such comparable existing license, program 24 program 24 will estimate the cost for the new license to license the unlicensed software installation based on a fixed, predetermined percentage (such as 25%) of the total license fee for the existing license plus the total license fee for the existing license divided by the number of copies licensed under the existing license.
After step 220 , program 24 notifies the administrator of this recommended resolution (step 230 ), and the estimated cost as noted above.
[0024] It should be noted that the order of the steps 204 , 208 , 212 , 216 and 220 is generally the order of lower cost to higher cost to the company of the resolution, i.e. to maximize the license cost reductions or minimize the additional license cost, as the case may be. In other words, complete removal of the software from all the computers of the company following step 204 will lower the cost to the company (if the existing licenses have ongoing charges). The removal of a single software installation following step 208 may also lower the cost to the company (if there is a license intended for the software installation, but is inadequate) but not as much as complete removal of the software from all the computers of the company. In other cases, the removal of the single software installation following step 208 will be neutral as far as cost. The relocation of the software from the currently unlicensed installation to another, licensed computer following step 212 will be neutral as far as cost to the company (except for the labor involved). The renegotiation/expansion of an existing license following step 216 will likely entail some additional cost to the company. The purchase of a new license following step 220 will likely entail greater cost than renegotiation/expansion of an existing license in step 216 . So, the earlier in the sequence of steps 204 , 208 , 212 , 216 and 220 that program 24 determines the respective resolution to be viable based on the rules in database 201 , the more economical the recommendation by program 24 to the company.
[0025] If program 24 reaches a recommendation in steps 204 , 208 , 212 , 216 or 220 to (a) decommission/delete the software from all computers of the company, (b) decommission/delete another installation of this software on another computer of the company so that an existing license has sufficient scope to license the currently unlicensed software installation, (c) move the currently unlicensed software to another computer where it will be properly licensed under an existing license of the company, (d) renegotiate an existing license of the company to extend the existing license to the currently unlicensed software installation, or (e) purchase a new license to cover the currently unlicensed software installation, then program 24 notifies the administrator in step 230 as explained above. In the illustrated embodiment of program 24 , when program 24 first determines satisfaction of one of the foregoing recommendations listed above in step 204 , 208 , 212 , 216 or 220 in that order, program 24 notifies the administrator of the recommendation (and cost) in step 230 , and does not consider the other possible resolutions which appear downstream/later in the flowchart of FIG. 2 . However, in another embodiment of program 24 , program 24 considers all the possible resolutions of steps 204 , 208 , 212 , 216 and 220 (and their respective costs) in the case of all installations of software being licensed properly, and notifies the administrator in step 230 which possible resolutions comply with the rules in rules database 201 and their cost. This allows the administrator to choose amongst all possible acceptable resolutions.
[0026] Programs 22 and 24 can be loaded into computer 10 from a computer storage medium such as magnetic disk or tape, optical CD ROM, DVD or the like onto RAM or hard drive, or downloaded from the Internet and TCP/IP adapter card 20 .
[0027] Based on the foregoing, a system, method and program product for determining what to do when an unlicensed software installation is identified, have been disclosed. However, numerous modifications and substitutions can be made without deviating from the scope of the present invention. For example, in the case of all installations of a software type being properly licensed, program 24 can determine if there are any opportunities to reduce the scope of the current licenses and, thereby, gain savings in future licensing costs. Therefore, the present invention has been disclosed by way of illustration and not limitation, and reference should be made to the following claims to determine the scope of the present invention. | A method and system for resolving an unlicensed installation of a type of software in a first computer of a company. The method and system: determines that the type of software is currently installed on a second computer of the company; determines that the company has an existing license permitting multiple copies of the software to be installed on the second computer; and based on the determination that the company has an existing license which permits multiple copies of the software to be installed on the second computer, determines, and generates a computer record indicating, that a solution to the unlicensed installation of the type of software on the first computer is to decommission the unlicensed software from the first computer and install another copy of the software in the second computer under the existing license in addition to the type of software currently installed on the second computer. | 6 |
BACKGROUND OF THE INVENTION
[0001] The invention concerns a directional microphone.
[0002] Modern hearing devices resort to directional microphone arrangements that, via their direction-dependent microphone sensitivity, enable an exclusion of unwanted signals coming from lateral and backwards directions. This spatial effect improves the wanted-signal-to-background-noise ratio, such that, for example, an increased speech comprehension of the wanted signal exists. The conventional directional microphone arrangements are based on an evaluation of the phase (delay) differences that result given a spreading sound wave between at least two spatially separate sound acquisition locations.
[0003] In hearing devices, until now, gradient microphones or, respectively, directional microphone arrangements of a first and higher order, comprising a plurality of omnidirectional acoustic pressure sensors, have been used for this. While the first determines the difference (stemming from the mechanical assembly) of the sound signals originating from two sound entrance ports, a good static or even adaptively variable directional effect can be achieved via suitable signal processing, given a combination of a plurality of acoustic pressure sensors.
[0004] However, all known methods evaluate the differences of the sound signals present at the sound entrance ports in the same manner. Since the distances between the sound entrance ports in hearing device applications are very small (conditional upon the type), this leads to the fact that, given deeper frequencies at which the sound wavelength is much larger than the separation of the microphone entrance ports, the differences to be determined between the audio signals, and thus also the directional effect to be achieved, are very small. Typically, all directional microphone arrangements possess a clearly reduced directional effect at lower frequencies; moreover, arrangements made up of a plurality of pressure sensors place very high demands on the amplitude and phase compensation of the microphones.
[0005] A differential pressure transducer is known from U.S. Pat. No. 4,974,117 that capacitively couples two membranes, where the pressure difference is measured between the pressure in the volume between the membranes and the pressure in the volume that surrounds both membranes.
[0006] In imitation of the acoustic organ of the “Ormia” fly, which achieves a unique directional effect with the aid of a mechanical coupling of two auditory membranes, various approaches to use mechanically coupled auditory membranes in hearing aid devices have been pursued. For example, in a microphone system based on silicon micromechanics, the vibration-capable membrane of two independent microphones arranged adjacent to one another are negatively coupled with one another via a web (see “Mechanically Coupled Ears for Directional Hearing in the Parasitoid Fly Ormia Ochracea”, R. N. Miles, D. Robert, R. R. Hoy, Journal of the Acoustical Society of America 98 (1995), pg. 3059).
SUMMARY OF THE INVENTION
[0007] The invention is based on the object of providing a directional microphone, as well as the use of a directional microphone in a hearing aid device, that lead to a good directional effect given the smallest possible structural shape.
[0008] The first cited object is achieved by a directional microphone with: two membranes that, on the one hand, are respectively acoustically connected via an air volume with one of two spatially separate sound entrance ports, and on the other hand are acoustically coupled with one another via a third air volume; and with a mechanism to generate at least one output signal of the directional microphone from the vibration of one of the two membranes.
[0009] The increased directional resolution of a directional microphone according to embodiments of the invention is achieved via the acoustic coupling of two independent membranes. The coupling ensues via a small air volume which is located between the membranes. If a sound wave impinges the directional microphone at a specific angle of sound incidence, the sound wave reaches both microphone membranes at different points in time. The sound wave is conveyed by the membranes to the volume between the two membranes. This effects a complex interaction of both mechanically vibration-capable membranes. Depending on the angle of incidence, an amplitude and phase difference appears between the sound waves affecting the membranes, due to the delay differences. Given a symmetric incidence in which the sound wave impinges both membranes simultaneously, the sound pressures fed into the acoustic coupling are equally large, meaning they are located at equilibrium. If the vibrations are measured with a mechanism to generate an output signal, for example with ordinary microphone sensors, in this case the output signals of both microphone membranes are, in the ideal case, equally large. In contrast, they differ given an asymmetric incidence of the sound wave.
[0010] This is advantageous in that such a directional microphone exhibits a very small and compact assembly. The dimensions of the assembly are predominantly given by the size of the membranes and by the air volumes that, on the one hand, produce the connection to the sound entrance ports and, on the other hand, couple the two membranes with one another. “Acoustic coupling” means a coupling that is generated by a sound wave that forms in the air in the third air volume. A further advantage is that, due to the acoustic coupling of the sound pressures present at both sound entrance ports, membrane vibrations are generated that are dependent on the angle of sound incidence.
[0011] In a particularly advantageous embodiment of the directional microphone, an electrical layer on one of the two membranes and a backplate (counter) electrode to this electrically conductive layer form a capacitive transducer element. Such a capacitive transducer element enables an output signal to be generated from the vibration of the membrane, and has the advantage that the technology of such “capacitive microphones” can be transferred to the directional microphone.
[0012] In an advantageous embodiment, the backplate electrode is arranged between the two membranes (that are arranged parallel to one another) in which a small air gap respectively lies between one of the two membranes and the backplate electrode. To ensure the acoustic coupling of the two membranes, the backplate electrode may comprise air ducts. This has the advantage that the coupling can be adjusted with regard to its strength with the aid of the size of the air ducts.
[0013] In a particularly advantageous development, both membranes are conductively coated and, with the backplate electrode, respectively form a capacitive transducer element. Each transducer element can generate an output signal which differs in its amplitude and in the phase, dependent on the direction of incidence of an acoustic signal, from the respective other output signal. The direction of incidence can be inferred using these differences.
[0014] In a particularly advantageous embodiment, the directional microphone additionally comprises a signal processing unit and an omnidirectional microphone, by which, with the aid of the signal processing unit, the microphone signal may be used to generate the output signal of the directional microphone corresponding to a directional characteristic. The omnidirectional microphone can either be integrated in a housing with both membranes, or the omnidirectional microphone can by fashioned as an independent unit with separation from the membranes. This embodiment has the advantage that, with the microphone signal of the omnidirectional microphone, a direction-independent comparison measurement is available that, with the aid of the signal processing unit, can be combined with the output signal that is based on the vibration or one or both membranes.
[0015] The invention is also directed to a method for utilizing a hearing aid device, comprising the directional microphone described above.
[0016] Further advantageous embodiments of the invention are described below.
DESCRIPTION OF THE DRAWINGS
[0017] FIGS. 1 through 5 illustrate a plurality of exemplary embodiments of the invention using.
[0018] FIG. 1 is a cross section illustrating the schematic assembly of a directional microphone with two membranes according to an embodiment of the invention;
[0019] FIG. 2 is a graph showing a simulated frequency dependency on magnitude and phase of an output signal that results for both membranes given a sound field that occurs at an angle of 12.5°;
[0020] FIG. 3 is a graph showing a direction-dependent sensitivity distribution of an output signal of an individual membrane at 300 Hz;
[0021] FIG. 4 is a graph showing a direction-dependent sensitivity distribution of an output signal of an individual membrane at 1600 Hz; and
[0022] FIG. 5 is a functional schematic diagram of a directional microphone system that comprises an omnidirectional microphone, a directional microphone with two membranes, and a signal processing unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] FIG. 1 shows a schematic assembly of an embodiment of a directional microphone 1 with a cylindrically formed housing 3 in the section along the cylinder axis 4 . Located in the housing 3 are two membranes 5 A, 5 B, preferably arranged perpendicular to the cylinder axis 4 , that are preferably attached air-tight to the housing 3 via mountings. The membranes 5 A, 5 B are in contact with air volumes 7 A, 7 B. If a sound wave impinges on the sound entrance ports 9 A, 9 B, it arrives in the air volumes 7 A, 7 B and effects an oscillation (vibration) of the membranes 5 A, 5 B, due to the pressure changed by the sound wave.
[0024] A third air volume 11 and a backplate electrode 13 are located between the two membranes 5 A, 5 B. The air volume 11 is comprised of two air gaps 14 A, 14 B that exist between the backplate electrode 13 and the two membranes 5 A, 5 B, as well as of air ducts 15 A, 15 B which infuse the backplate electrode 13 . The air ducts 15 A, 15 B are, for example, round air channels running parallel to one another and substantially perpendicular to the membranes. The air volume 11 effects an acoustic coupling of the two membranes 5 A, 5 B that leads to a negative coupling since, in the case, for example, that the membrane 5 A vibrates outwards due to an occurring sound field considered from the middle of the directional microphone 1 , the opposite membrane 5 B is moved towards the middle of the directional microphone 1 due to the negative coupling.
[0025] The membrane 5 A comprises a penetration opening 17 that enables a barometric pressure equalization of the air volume 11 via the air volume 7 A connected with the environment.
[0026] If, for example, a sound wave impinges the directional microphone 1 from 270°, corresponding to the indicated angle scale, the membrane 5 A will initially begin to vibrate. Due to the vibration of the membrane 5 A, the air volume 11 undergoes a pressure change and transfers this to the membrane 5 B, such that the membrane 5 B also begins to vibrate. This vibration is superimposed with the sound wave occurring in the volume 7 B at a later point in time. The sound pressure of the sound wave in the volume 7 B is, for its part, transferred via the vibration of the membrane 5 B to the air volume 11 , which in turn effects the coupling with the membrane 5 A.
[0027] The acoustic-electric conversion of the vibrations of the membranes 5 A, 5 B can, for example, ensue with the aid of a capacitive transducer system. In such a system, a type of plate capacitor is formed from the backplate electrode 13 and an electrically conductive layer 19 A, 19 B on one of the membranes 5 A, 5 B. In such a capacitor microphone, the capacitor is charged by way of a polarization voltage. Based on the sound signals, the distance changes between the layer on the membrane 5 A, 5 B and the backplate electrode 13 , and a capacitance change of the capacitor arises which is detected with an electronic impedance transducer and is converted into an electrical voltage. Alternatively, an electret-capacitor microphone can be used in which an electric charge is permanently stored on the membrane 5 A, 5 B or on the surface of the backplate electrode 13 . The use of digital microphone transducer technology or plunger coil transducer technology can also be utilized for acoustic-electric conversion.
[0028] FIG. 2 reproduces a frequency dependency on amount A and phase φ, simulated for the membranes 5 A, 5 B. An angle of sound incidence of 12.5° (using the angles indicated in FIG. 1 ) and a distance of the microphone entrance ports of 4 mm is assumed. In the upper part of the image, the amounts A 5A , A 5B of both membrane vibrations are mapped over the frequency f in a frequency range of 10 Hz through 10 kHz. In the lower part of the image, the output signals are shown corresponding to the curve of the phases φ 5A , φ 5B . Given an angle of sound incidence of 12.50, a delay difference of 2.5 μsec results for the sound wave incident on both membranes 5 A, 5 B. In this minimal difference, a clearly detectably difference already shows between the two microphones in amount A and phase φgiven a frequency of 300 Hz. With additional frequency f, the difference becomes ever more developed.
[0029] FIG. 3 shows a simulated direction-dependent sensitivity distribution 21 5A of an output signal of the “left” membrane 5 A at 300 Hz. This “directional characteristic” is normalized to the sensitivity given an angle of sound incidence of 0°, which is normalized to the value 1 and is clarified by the circle N. The angle graduation corresponds to that of FIG. 1 . A clearly higher sensitivity on the side associated with the membrane 5 A is recognizable, as well as a lower sensitivity on the other side. Additionally, there is a significant phase difference between the output signals of the two membranes 5 A, 5 B.
[0030] FIG. 4 shows a corresponding sensitivity distribution 23 5A of an output signal of the “left” membrane 5 A at 1600 Hz. The structure of this directional characteristic is dominated by two regions of increased sensitivity that are located at 90° and 270°. Likewise, the sensitivity is greater on the side associated with the membrane 5 A, and significant phase differences between the output signals exist.
[0031] FIG. 5 shows a functional schematic of a directional microphone system 25 that comprises an omnidirectional microphone 27 , a directional microphone 29 with two membranes, and a signal processing unit 31 . One or both signals of the membranes of the directional microphone 29 are mixed with the signal of the omnidirectional microphone 27 in the signal processing unit 31 into a output signal present at an output 32 , with which a directional characteristic 33 is associated. The signal processing unit could additionally monitor the mixing, such that the directional characteristic is adapted to the sound field.
[0032] In a simple embodiment, only one signal of a membrane (which alone represents an improvement over a gradient microphone with regard to the directional sensitivity) is used, and is possibly operated together with an omnidirectional microphone in a housing or in separate housings.
[0033] For the purposes of promoting an understanding of the principles of the invention, reference has been made to the preferred embodiments illustrated in the drawings, and specific language has been used to describe these embodiments. However, no limitation of the scope of the invention is intended by this specific language, and the invention should be construed to encompass all embodiments that would normally occur to one of ordinary skill in the art.
[0034] The present invention may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of hardware and/or software components configured to perform the specified functions. For example, the present invention may employ various integrated circuit components, e.g., memory elements, processing elements, logic elements, look-up tables, and the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. Similarly, where the elements of the present invention are implemented using software programming or software elements the invention may be implemented with any programming or scripting language such as C, C++, Java, assembler, or the like, with the various algorithms being implemented with any combination of data structures, objects, processes, routines or other programming elements. Furthermore, the present invention could employ any number of conventional techniques for electronics configuration, signal processing and/or control, data processing and the like.
[0035] The particular implementations shown and described herein are illustrative examples of the invention and are not intended to otherwise limit the scope of the invention in any way. For the sake of brevity, conventional electronics, control systems, software development and other functional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail. Furthermore, the connecting lines, or connectors shown in the various figures presented are intended to represent exemplary functional relationships and/or physical or logical couplings between the various elements. It should be noted that many alternative or additional functional relationships, physical connections or logical connections may be present in a practical device. Moreover, no item or component is essential to the practice of the invention unless the element is specifically described as “essential” or “critical”. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the present invention.
[0000] Reference List
[0000]
1 directional microphone
3 housing
4 cylinder axis
5 A, 5 B membrane
6 mounting
7 A, 7 B air volume
9 A, 9 B sound entrance port
11 air volume
13 backplate electrode
14 A, 14 B air gap
15 A, 15 B air gap
15 A, 15 B air channel
17 permeation opening
18 A, 19 B electrically conductive layer
A, A 5A , A 5B amount
φ, φ 5A , phase
φ 5B
F frequency
21 5A , 23 5A sensitivity distribution
N circle
25 directional microphone system
27 omnidirectional microphone
29 directional microphone
31 signal processing unit
33 directional characteristic | A directional microphone system comprises two membranes that, on the one hand, are respectively acoustically connected via an air volume with one of two spatially separate sound entrance ports, and on the other hand are acoustically coupled with one another via a third air volume, as well as an output generator configured to generate at least one output signal of the directional microphone from the vibration of one of the two membranes. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to rear wheel suspensions for bicycles. In particular to such suspensions that mount the rear wheel on a swing arm so that, in response to vibration and shocks, the wheel is able to move along a path relative to the bicycle frame against counteracting forces applied to the swing arm by a shock absorbing mechanism.
2. Description of Related Art
Rear wheel suspensions for bicycles of the initially-mentioned type have been known for over a century. While such suspensions have taken on numerous forms (see, e.g., British Patent No. 3982, German Patent No. DE 40 41 375, and U.S. Pat. Nos. 392,523; 423,471; 463,710; 465,599; 2,756,071; 3,982,770; and 5,335,929), constant factors have been the fact that wheel movement has been controlled to move in an arcuate path, in most cases being dictated by the presence of a fixed, single (real or virtual) pivot connection between the frame and the suspension to which the rear wheel is mounted, and the fact that bicycles with these suspensions never were able to find more than limited public acceptance.
The reasons why the prior rear wheel bicycle suspensions never attained wide public acceptance, despite their ability, to a greater or lesser extent, to effectively absorb shocks and vibrations, lie in the fact that they introduced other behavior characteristics that were more disturbing than the shock and vibration problems they solved. That is, unless the pedal crank pivot was mounted at or near the pivot connection of the swing arm to the frame, the vertical component of the swing arm movement would adversely impact on the pedaling "feel" and the rider's ability to effectively apply a constant force to the pedals during riding. Furthermore, since the pedals, and therefore the pedal crank pivot, must be located near the middle of the bicycle (underneath and slightly forward of the seat), a bicycle with such a suspension produces a center hinge effect which leads to several problems affecting riding comfort and performance. In particular, a tendency exists for the front half (main frame) of the bicycle to rock about the pivot connection between it and the swing arm. This rocking movement changes the head angle and is perceived as a bobbing effect similar to riding a children's "rocking horse". Moreover, the suspension can act to absorb a portion of the pedal forces, affecting performance, and this absorption is translated into movement of the suspension, again, affecting riding "feel". Similarly, application of braking forces to the rear wheel would, in reverse, be transmitted into the suspension causing the rider to experience a "sinking" effect. Existing systems have faced have faced one or more other problems as well including traction and braking inconsistencies, and handling inconsistencies under competition conditions, to name just a few.
With the advent of professional bicycle racing, not merely road or track racing, but mountain or dirt bike racing, cross country and downhill (where bicycles travel downhill over rough terrain at speeds of around 40 mph (67 kph)), the demand for high performance bicycle rear suspensions has increased, while the problems of prior bicycle suspensions have been amplified under such racing conditions. That is, the forces to which the suspension is subjected require increased wheel travel to absorb the induced shocks as well as the need to use softer springs for bump compliance (i.e., so that the wheel will follow the bump instead of bouncing off it) for traction purposes. However, changes of this type make previously "invisible" force problems not only apparent, but unacceptable. Put another way, as wheel travel increases, the importance of maintaining consistent (and constant) force functions within the bicycle-rider system increases and this has been obtainable, to date, in most rear suspensions only by the use of very stiff springs to correct for geometry induced problems (many suspensions also limit downward wheel travel from static ride height to zero), thereby sacrificing bump compliance.
In contrast to bicycles, motor vehicle, and particularly motorcycle, rear (drive) wheel swing arm suspensions have been developed which do not use a single pivot motion mechanism. For example, in U.S. Pat. No. 4,735,277, motorcycle drive wheel suspensions are disclosed which use at least two swing arms, one of which is connected to the cycle frame and a second of which is connected to the wheel, in a way which permits the rear wheel to freely move in any direction relative to the frame within the plane of rotation of the wheel and allowing the wheel to move along a plurality of paths. However, considering that this patent contains no disclosure as to what purpose is served by permitting the rear wheel to freely move in any direction relative to the frame within the plane of rotation of the wheel and allowing the wheel to move along a plurality of paths, and given the performance, applied load and ride differences between motorcycles and bicycles, not to mention the presence of a frame-mounted motor instead of a suspension-mounted pedal crank, no practical means or reason to apply such a suspension to a bicycle can be derived from this patent.
Likewise, U.S. Pat. No. 4,671,525, discloses a suspension for the rear wheels of motor vehicles in which the wheel-carrying swing arm forms part of a quadrilateral linkage assembly in which the shock absorbing members can be located between any members and the geometry of the articulated system can be designed to produce movement of the rear wheel along any desired path, the described embodiment attaining an almost linear or slightly curved path having a substantially vertical, upward and rearward inclination. However, while the advantages of this suspension, in addition to being able to be adapted to produce any desired path of movement, are indicated as including its ability to counteract "sinking during an acceleration" and "raising when braked," due to its ability to perform a long elastic excursion, no particular significance is attached to any particular linkage configuration or resultant path of movement relative to this advantage or any other. Thus, since this patent also relates to motor vehicles having a frame-mounted motor instead of a suspension-mounted pedal crank, no practical means or reason can be obtained from this patent to apply such a suspension to a bicycle, again, recognizing the differences in performance, ride and applied forces occurring in the motorcycle context in comparison to bicycles.
Thus, a need still exists for a rear wheel suspension for bicycles which will overcome the above-mentioned problems associated with bicycle swing arm suspensions as they have been constructed to date, and no means to fill that need frown existing motorcycle rear wheel suspensions being apparent. In particular, a need exists for a bicycle rear wheel suspension which will meet the needs of competitive mountain bike racing.
SUMMARY OF THE INVENTION
In view of the foregoing, it is a primary object of the present invention to achieve a swing arm type rear wheel suspension for a bicycle which will avoid the above-mentioned problems associated with prior bicycle suspensions of this type.
In keeping with the foregoing object, a further object of the present invention is to develop a high performance, swing arm type rear wheel suspension for a bicycle having a multi-link swing arm assembly that is particularly adapted to the needs of bicycles, especially mountain bikes for downhill racing, from such standpoints as proper pedal crank location and "feel", wheel excursion path, traction and braking performance, etc.
Still a further object of the present invention is to provide a rear wheel suspension for a bicycle which can be attached to standard bicycle frames with minimal modifications.
These and other objects are achieved in accordance with the present invention. In particular, a preferred embodiment of the invention utilizes a three link suspension assembly that is formed of an essentially horizontal swing arm which is pivotally attached at one end to the underside of the frame by a pair of short links and which carries the rear wheel at an opposite end. The geometry of the suspension assembly is designed to produce an essentially straight line trajectory of the rear wheel in an upward and rearward direction at an angle that is preferably 20°-30° with respect to a vertical line through the wheel axis of rotation to increase traction, making the acceleration forces apply an upward vertical force component to the frame independent of wheel position, and a downward force to the frame under braking which helps to control the frame attitude. Furthermore, to obtain a constant pedal "feel," the suspension geometry is also designed so that the maximum vertical height movement of the pedal crank axis of rotation can be kept to less than 5% of the vertical wheel travel (e.g., a 0.25" crank axis height increase for a 4" vertical wheel travel). The suspension is designed to attach to a frame of a standard shape leaving room for mounting of the derailleur between the frame and the rear wheel. In a particularly preferred form, the swing arm assembly is provided with a tubular derailleur mount and an upper tube to which the rear wheel brake assembly can be mounted.
These and other features of the invention are described below in greater detail with respect to preferred embodiments of the invention and in conjunction with the accompanying figures of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A & 1B are schematic depictions of a virtual single pivot swing arm as compared to a real single pivot swing arm;
FIGS. 2, 3 and 4 are schematic force diagrams for purposes of describing the behavior of conventional single pivot, swing arm rear wheel suspensions;
FIG. 5 is a diagrammatic depiction of the production of a straight line trajectory for rear wheel travel via a three link swing arm assembly in accordance with the present invention;
FIGS. 6 and 7 are schematic diagrams of a first embodiment of the present invention;
FIGS. 8-10 are schematic diagrams illustrating alternative suspension configurations in accordance with the first embodiment of the present invention;
FIG. 11 shows a most preferred embodiment of the invention;
FIG. 12 shows an enlarged perspective view of a lateral stabilizing mechanism of the FIG. 11 embodiment; and
FIG. 13 an alternative form for the lateral stabilizing mechanism;
FIGS. 14(A)-(C) show other relative positions for the converging links relative to the crank of the suspension;
FIGS. 15 & 16 show two forms for the pivot links and their connection to the swing arm of the suspension; and
FIG. 17 shows a pivot link of the arrangement shown in FIG. 16.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to place the present invention in context, it is important to recognize the source of problems associated with conventional single pivot swing arm bicycle suspensions, whether the connection of the swing arm to the bicycle frame is achieved via a real single pivot (FIG. 1A), e.g. a single swing arm sa connected to a bicycle frame F at a fixed location corresponding to pivot axis P or via a virtual single pivot (FIG. 1B), i.e., a multi-link system in which the system pivots the wheel axis z about a pivot axis P which is located at a point in space at which the center line of a pair of swing arms sa converge. Likewise, it is important to point out certain basic constraints within which the designer of a bicycle suspension must work to produce a suspension that is usable with bicycle frames, pedal cranks, wheels, etc., which are conventionally constructed.
Thus, initial reference is made to FIG. 2 in which a bicycle equipped with a single pivot swing arm is diagrammatically depicted connected to a bicycle frame for rotation about pivot axis P. When the swing arm sa is horizontal, a line through the axes P and z is parallel to the ground, so that a drive force F 1 is applied to the frame and no vertical force component acts on the system at pivot axis P or on the wheel at axis z. However, as the wheel moves up relative to the frame and axis P through an angle Θ, the drive force F 1 , e.g., when it hits a bump as represented in FIG. 3, an upwardly directed vertical force component F 2 appears at wheel axis z and a downwardly directed vertical force component F 3 appears at pivot axis P. These instantaneous forces at P and z are equal to F l sin Θ and is equal to half the driving force F 1 when Θ is 30°.
The significance of these vertical components is that when, as shown, the wheel axis z is raised above the pivot axis P, the vertical force component F 2 is directed upward and subtracts from the traction that the rear wheel can generate. Furthermore, the vertical force component F 3 introduced at P can cause the frame F to move up or down. Additionally, for a given rear wheel travel, as the distance between P and z is shortened, Θ increases and so do the vertical force components variations, traction functions, attitude variations, etc. Clearly then, longer swing arms for a given wheel travel is desirable since such will reduce force variations as a function of vertical wheel position for any trajectory by reducing Θ toward zero. However, bicycle swing arms are typically 13-24" long, the distance between the driving sprocket and the driven sprocket (i.e., between axes P and z) is from 16.5-17.5" and the maximum permissible wheel travel set at about 3-4" (this being dictated by the minimum pedal-to-ground clearance given a pedal crank axis mounting height of 12-13" and an 8" distance from the pedal crank axis to the bottom of the pedal and standard wheel diameters of 26-28"). Thus, these constraints lead to large Θ changes for all conventional single pivot rear wheel suspension swing arms, and in turn, to traction and frame attitude variations.
Another factor of significance is braking. Not only are the independently actuated brakes of a bicycle used to stop it, but under racing conditions the brakes are use to control the height and attitude of the bicycle when entering corners (sometimes the rear or front brake is used to "set" the bike's attitude while drifting, i.e., a two-wheel slide, into a corner). When the rear brake is applied, a retarding force acts between the fires and the ground which the bicycle experiences as a force F B that is directed rearward and parallel to the ground at wheel axis z. The force F B must be great enough to overcome the mass of the bicycle and its rider, which mass is centered above the height of the front wheel axis. As a result, a significant moment about axis z is created that is proportional to the mass of the bicycle and rider, the height of the mass center above the rear wheel axis z, and the deceleration rate. With reference to FIG. 4, it can be seen that, for a single pivot swing arm, this braking force F B results in a downward force F 4 at axis P and a like upward force F 5 at axis z, which act to counteract the mass moment and which increase as the length of the swing arm is decreased. As such, since it is these forces that are used to control bicycle height and attitude, increasing the length of the swing arm to minimize problems of traction and frame attitude variations during riding would counteract the ability of the rider to use the brake caliper forces to enhance anti-lift.
In the above context, the nature and significance of the developments according to the present invention will now be explained. As pointed out above, for a given wheel travel, the longer the swing arm, the smaller the vertical force component imposed on the bicycle which can affect wheel traction and frame attitude, yet in the bicycle context constraints exist which severely limit the length which the swing arm can be made. To overcome the limitation, the present invention utilizes the fact that extremely long swing arms cause the wheel to travel along an arcuate trajectory that approaches a straight line path. Thus, the present invention utilizes a three-link swing arm assembly to produce a rear wheel trajectory which is essentially a straight line so as to produce the effect of an essentially infinite length single pivot swing arm.
However, as also described above, a long swing arm length will defeat the ability of the rider to control bicycle height and attitude by the application of braking forces. This problem is addressed in accordance with the present invention by making the swing arm rotate and translate so as to produce a linear or slightly radiused rear wheel trajectory in a manner which is not related to the apparent effective length of the swing arm, so that the caliper can "think" it is mounted on a short swing arm to produce the desired anti-lift function. This is achieved by pivotally connecting the "long" swing arm to the frame via a pair of minimum length pivot links. In this regard, FIG. 5 diagrammatically depicts how the swing arm sa can pivot as does a conventional short swing arm, in conjunction with swinging of pivot links L 1 and L 2 yet the wheel axis z can follow a straight line trajectory T at a rearward angle Θ (preferably 20°-30°) that is set to produce the desired braking force anti-lift component and a vertical component F 2 , in response to a forward driving force, that acts downward to increase traction over bumps. In the case where the suspension of the present invention is to be applied to a bicycle equipped with a front fork suspension, advantageously, the angle Θ is matched to the angle of the trajectory of movement of the front wheel, such being conventionally around 18°-22°, since this can increase the dynamic stability of the bicycle.
Specific embodiments for implementing the developments according to the present invention will now be described. In this regard, it is noted that while only a single swing arm assembly (swing arm and connecting links) is described below, it should be appreciated that all embodiments of the present invention possess a pair of identical swing arms SA at each of opposite lateral sides frame and rear wheel of the bicycle. These swing arms may be connected to a common upright or may be separate, and in either case, they are coupled to the frame F by the pivot links L 1 and L 2 , as described below and particularly as shown in FIGS. 15-17.
FIG. 6 shows a bicycle 1 having a frame F, a front wheel 3 that steerably connected to the frame F, a rear wheel 5 that is driven by a pedal-operated chain drive assembly 7, all of conventional design. Additionally, a rear wheel suspension 10 of the pivoting swing arm type is provided which has a swing arm SA having standard wheel axle mounting notches 9 for connecting the rear wheel 5 to a first end thereof. A pedal crank C of the chain drive assembly 7 is rotationally mounted on the swing arm SA as is a mount BR for a brake caliper B.
For pivotally connecting the swing arm SA to the frame F of the bicycle near a second end thereof, a pair of upwardly converging links L 1 , L 2 are provided that are relatively short in comparison to swing arm SA, preferably, having a length that is no more than about 10% of the length of the swing arm. A first end of the converging links L 1 , L 2 are pivotally connected to the swing arm SA at P 2 , P 4 near a location at which pedal crank C is rotationally mounted, and a second end thereof is connected to frame F near a lower end thereof at P 1 , P 3 . Any form of known shock absorbing means (spring, elastomer, air, hydraulic or hybrid combination thereof) can be connected between the bicycle frame and the suspension at any location thereof; but, in accordance with the present invention, preferably, the connection of a shock absorber 11 to the suspension 10 is provided by a pivotal connection of the shock absorber 11 to an extension of one of the links L 1 , L 2 , such as at pivot point P 3 shown in FIG. 7, since this allows connection to a point which moves linearly with respect to wheel travel and thereby enabling a linear spring rate curve to be achieved.
An import aspect of the invention is the providing the converging links L 1 , L 2 and swing arm SA with a geometry which produces a trajectory T-T' of rear wheel travel movement at the second end of the swing arm which is a substantially straight line path, preferably at an angle Θ of between 20°-30° and which, at the same time, restricts the maximum vertical movement of the pedal crank to within a range of about 5% to 10% of rear wheel vertical travel based upon a percentage of about 5% for a rear wheel vertical travel of about 4" and a percentage of about 10% for a rear wheel vertical travel of about 2", i.e, the crank axis follows a path t-t' which produces a vertical height displacement of, e.g., 0.25" or less. Various computer programs are available that can be used to determine suitable geometries for the links and swing arm to produce these results are, given the above-mentioned size constraints and the trajectory to be produced, or such can be determined empirically. In this regard, solely by way of example, a swing arm SA of 17" has proved suitable for use with links L 1 and L 2 of 1.44" and 2.3" respectively to achieve a substantially straight line wheel travel of 4.0".
FIGS. 8-10, by way of example only, show other possible configurations for link L 1 and placement of shock absorber 11, the arrangement of FIG. 9 offering the advantage of leaving an area xx free for placement of the derailleur of a standard gear shift mechanism. Likewise, FIGS. 14A-C show other relative positions for the converging links L 1 , L 2 relative to the crank C. Changing of the link positions will affect their length, but generally, the link L 1 will be always be about 60-70% of the length of L 2
FIGS. 11 and 12 show a most preferred embodiment of the present invention. In this embodiment, the swing arm SA is part of a triangular frame-shaped assembly 14 having an upright 15 positioned near the location at which said pedal crank is rotationally mounted and a crosspiece 16 that extends between the upright 15 and the end of the swing arm SA that is connected to the rear wheel 5. This complete assembly 14 attaches to the bicycle frame F by a single bracket 17 at a single interface surface, thereby limiting the modification which must be made to frame F to the provision of a mounting surface for bracket 17. A rear wheel brake mount BR for a brake caliper is provided on crosspiece 16 and a mount 18 for the derailleur of a gear shift mechanism is provided on the upright 15 of the frame-shaped assembly 14.
This triangular configuration of the assembly 14 provides increased structural rigidity. Moreover, a lateral support means 20 can be carried by the upright 15. The lateral support means 20 serves for restricting lateral deflection of assembly 14 in a manner which will not affect the trajectory T-T' of rear wheel travel movement produced by the geometry of converging links L l , L 2 and swing arm SA. In a first form, the lateral support means 20 comprises a pair of scissor links L 3 , L 4 that are pivotally connected to each other, scissor link L 3 being pivotally connected to the seat post 22 of the bicycle frame F and the scissor link L 4 being pivotally connecting to the upright 15. The scissor links L 3 , L 4 can be very small, e.g., only 1" between pivot connections, since they serve only for lateral stability and need only execute a very small vertical displacement of the pivot point on upright 15. As such they do not constitute an appreciable added weight.
An alternative form of lateral support means 20' comprises a fork-shaped bracket 25 connected to the top of upright 15. Bracket 25 has a pair of guide arms 26, 27 which slidingly straddles the seat post 22 of the bicycle frame F.
As mentioned above, the two swing arms SA, whether separate or connected, are preferably joined to the frame by a single pair of links L 1 and L 2 . The reason for this is that use of a single pair of links (instead of to pairs of links) enables the links L 1 , L 2 to resist lateral loads and optimally also torsional deflections. In FIG. 15, solid links L 1 , L 2 are shown mounted on pins which extend between rigid plate-shaped extensions of the assembly 14. In contrast, FIG. 16 shows an assembly 14 having a solid link-mounting extension to which the H-shaped links L 1 , L 2 shown in FIG. 17 mount. The H-shaped links L 1 , L 2 shown in FIG. 17 are also suitable for use when separate swing arms SA are used instead of the assembly 14.
While various embodiments in accordance with the present invention have been shown and described, it is understood that the invention is not limited thereto, and is susceptible to numerous changes and modifications as known to those skilled in the art. Therefore, this invention is not limited to the details shown and described herein, and includes all such changes and modifications as are encompassed by the scope of the appended claims. | A suspension assembly that is formed of an essentially horizontal swing arm which is pivotally attached at one end to the underside of a bicycle frame by a pair of short links and which carries the rear wheel at an opposite end. The geometry of the suspension assembly is designed to produce a substantially straight line trajectory of the rear wheel in an upward and rearward direction at an angle that is preferably 20°-30° with respect to a vertical line through the wheel axis of rotation to increase traction, making the acceleration forces apply an upward vertical force component to the frame, and a downward component to the frame under braking, independent of wheel position, that reduces rear frame lift (pitch). Furthermore, to obtain a constant pedal "feel," the suspension geometry is also designed so that the maximum vertical height movement of the pedal crank axis of rotation can be kept to less than 5% of the vertical wheel travel (e.g., a 0.25" crank axis height increase for a 4" vertical wheel travel). The suspension is designed to attach to a standard frame leaving room for mounting of the derailleur between the frame and the rear wheel. In a particularly preferred form, the swing arm assembly is provided with a tubular derailleur mount and an upper tube to which the rear wheel brake assembly can be mounted. | 1 |
CROSS-REFERENCES TO RELATED APPLICATION
The present disclosure is a continuation-in-part of my earlier filed Application Ser. No. 710,565 filed Aug. 2, 1976 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the art of papermaking. In particular, the present invention describes a method and apparatus for improving the web formation of fourdrinier screen laid paper.
2. Description of the Prior Art
The papermaking process generally comprises a series of drying steps whereby a continuous flow of wood fiber suspended as a dilute aqueous slurry called stock is consolidated, first, to a wet fibrous mat and finally, to a dry finished paper web.
The fourdrinier papermachine on which this drying sequence is performed comprises first, a wet or forming section followed by a press section and a dryer section. Depending on the product objective, the dryer section may be followed by a calender finishing section.
The forming section of a papermachine comprises a flow receiving vessel for the stock. This vessel, called a headbox, is provided along the bottom thereof with a narrow slit opening called the slice. The slice constitutes the flow regulation device for control of stock flow from the headbox onto a perforate belt called the fourdrinier screen. This screen is driven around a closed belt course which includes a substantially horizontal portion called the table. Stock flow from the slice onto the screen forms a standing pond of stock on the screen along the table. Before the pond is allowed to flow over the lateral edges of the screen, sufficient water is drawn from the stock through the screen by various suction devices located beneath the table. By this action, the fiber, which originally constituted only about 0.5% of the slurry on the dry weight basis, is poured upon the screen as a low viscosity fluid and is removed therefrom at the end of the table as a consolidated fibrous mat.
From the wet end forming section, the fibrous mat is carried into the papermachine press section where additional water is removed mechanically by the squeezing action of a series of low pressure roll nips to form a compacted paper web.
Following the press section, the web is directed into the dryer section comprising a series of heated drums over which the web is threaded. The dryer section removes remaining water from the web evaporatively.
Final caliper and surface finishing of the dry web is achieved in the calender section by a series of high pressure nip rolls.
For purposes of product quality control and machine adjustment, most modern papermachines are equipped with instruments, usually located after the dryer section, to monitor the web characteristics of moisture, basis weight and conditioned weight. Sensors for these instruments continuously reciprocate across the web in the cross-direction (CD) while the web travels longitudinally along the machine-direction (MD) therebeneath. When data from these instruments is visually displayed by a chart recorder or cathode ray tube, a CD profile of the measured characteristics is revealed.
The basis weight characteristic relates to the total mass of web material, water plus fiber per unit of web area; usually per 1000 ft. 2 or per ream (3000 ft. 2 ). Since the moisture content of the web is measured independently of the basis weight, these two characteristic values may be combined to derive the characteristic of conditioned weight which is the measure of fiber quantity, exclusive of water, present in the web per unit of area.
It is the objective of every papermaker to achieve a uniform distribution of conditioned weight and moisture throughout the web in both, the CD and MD directions thereof. However, the mechanics of variations in these characteristics are different with respect to the CD and MD directions.
In the MD direction, magnitude variations in conditioned weight are predominantly due to random occurrences of fiber floccing: in other words, uncontrolled consolidation of fiber groups occurring in the headbox or before. Poor fiber distribution due to floccing is manifested in the finished sheet by a mottled or splotchy appearance.
Conditioned weight variations that are stable as to magnitude and CD location, on the other hand, are predominately the result of CD variations in the headbox slice opening. This paper web defect is seen in the finished product as light and dark streaks of web density.
CD moisture variations that are stable as to magnitude and CD location are normally an additional consequence of an improperly adjusted slice opening. Under such circumstances, a stable, high moisture region in the CD moisture profile is also attended by correspondingly high basis weight and conditioned weight magnitude profiles. However, on occasion, a stable high moisture region in the CD profile will not be attended by a conditioned weight concentration. This is a circumstance more apt to be caused by turbulence and flow characteristics internal of the headbox. Accordingly, the condition may not be readily affected by manipulation of the slice opening.
It would seem that a zone in the finished paper web that is uniform as to conditioned weight would be acceptable notwithstanding moisture variations. However, localized moisture variations affect the dimensional stability of the finished web and for this reason, all increments of the web must be dried to a threshold minimum moisture content. Consequently, if the web is burdened with a narrow, high moisture zone along the center thereof, the lateral remainder of the web must be over-dried in order to drive the high moisture zone below the threshold minimum. The overall result of these circumstances is an inefficient expenditure and waste of thermal energy in the papermachine dryer section on 90% of the web area, for example, to dry 10% of the web to tolerance.
From the perspective of moisture concentrations unattended by conditioned weight concentrations, it would be of great value to a papermachine operator to selectively adjust the moisture distribution in the web prior to the dryer section but independently of the fiber distribution.
U.S. Pat. No. 3,407,114 discloses a prior art technique for correcting a poor CD fiber distribution condition whereas U.S. Pat. No. 2,951,007 discloses a technique of selectively adding water to a predominantly finished web having a poor CD moisture distribution condition. In addition, U.S. Pat. No. 1,989,435 teaches a technique of altering the cross-directional strength of a paper web by impinging the fourdrinier pond with a pair of CD oriented curtain sprays.
U.S. Pat. No. 3,989,085 of William E. Crosby, having the assignee in common with that of the present application, describes a method and general apparatus for correcting the formation profile of a cross-directionally located anomaly. Due to the relevance of William E. Crosby's disclosure to the present invention, the disclosure thereof is hereby incorporated by reference.
Generally, Crosby's method included an array of fluid spray sources disposed above and across the fourdrinier table to direct a linked series of CD elongated fan spray patterns of fluid into the pond at select CD locations.
The apparatus of W. E. Crosby's disclosure anticipated several techniques of volume control for the described formation profile correction method, the most basic being the manually adjustable flow control valves.
For the purpose of automatic control, variable volume pneumatic valves were implied. Automatic electrical flow control was described relative to solenoid operated valves which are normally considered as binary operators, such valves having only two operative positions of entirely closed or completely open. This type of control, however, prohibits volume control in the sense of regulation.
Although electrically operated proportional valves are available to the art for electric powered automatic flow regulation, expense greatly inhibits the use of such devices. Regardless of whether the flow control is manual or automatic, regulation in the manner described is accomplished by flow throttling which has the consequence of pressure reduction. Since spray impact velocity is a significant factor in this profile control, pressure reductions due to flow rate throttling have adverse effects on the profile correction objective.
Moreover, fixed orifice nozzles secured to the distal ends of the several CD distributed conduits downstream of each flow control valve are designed to issue a precise pattern at a particular combination of flow rate and pressure drop. If this combination is significantly changed, so, too, is the nozzle spray pattern. Accordingly, over a full range of flow rate variation, the spray fan width may change 50% or more. Consequently, at the upper end of the flow rate range, adjacent spray fans may overlap excessively thereby flooding the overlapped swath. On the lower end of the flow rate range, adjacent spray fans will not meet thereby leaving strips in the pond unaffected by the sprays.
SUMMARY OF THE INVENTION
It is, therefore, an objective of the present invention to teach the construction of a web profile correction system having an adequate degree of flow regulation accomplished with the simplicity of a binary command system. Another object of the present invention is to teach a web profile corrective spray system having a variable flow rate without affecting the spray impact velocity or fan width.
Another object of the present invention is to teach the construction of a spray system for web profile correction wherein each spray station across the web CD is serviced by three binary command flow valves activating different capacity spray nozzles to achieve eight distinct flow rates over the full flow control range.
These and other objects of the invention are accomplished by means of a single fluid supply manifold extended across the CD of a papermachine fourdrinier in the vicinity of the headbox slice opening. At each spray station across the machine (approximately 6 inch spacings) three independent spray conduits are connected with the manifold. Between the manifold and a fixed orifice fan spray nozzle at the distal end of each conduit is a binary command solenoid valve.
The three spray heads respective to each spray station are positioned to impact the web pond along the same CD line located between the slice landing and the fourdrinier "dry line." Additionally, each spray head of a respective station is preferably restricted to a different flow rate whereby select flow combinations from respective spray heads will provide uniform flow rate differential increments over the total flow spectrum up to the maximum flow rate capacity of the station.
A specific example of the invention teaches a control panel array of one cascade rotary switch for each spray station and an orifice restriction of 1, 2 and 4 gpm flow rate respective to the three spray heads. Consequently, a combination of eight flow rates of from zero to seven gallons-per-minute may be applied to the pond in one gallon-per-minute differential increments.
BRIEF DESCRIPTION OF THE DRAWING
Relative to the drawing wherein like reference characters designate like or similar elements throughout the several figures:
FIG. 1 illustrates a profile schematic of a fourdrinier papermachine;
FIG. 2 illustrates an enlarged schematic of the headbox end of a papermachine equipped with the present invention.
FIG. 3 illustrates a typical electrical control circuit for the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For purposes of orientation, FIG. 1 schematically illustrates a typical fourdrinier papermachine comprising a web formation section A, a wet press section B, a dryer section C and a calender section D.
The web formation section A comprises a headbox 10 having a slice opening 11 located at the headbox bottom above the fourdrinier screen 12. A series of suction boxes 13 are spaced along the screen table 14 between the slice 11 and the couch roll 15.
Illustrated by FIGS. 2 and 3 is the profile control system particular to the present invention comprising a fluid manifold 21 having a plurality of equally spaced extensions 22 depending therefrom. Each extension 22 services a respective spray station 20a, 20b, 20c, etc. along the manifold line and is provided with a flow obstructing valve 23 between the spray station appurtenances and the manifold 21.
Below each valve 23 is a sub-manifold distributor 24 having three outlet ports for conduits 25, 26 and 27, respectively. In the flow line of conduits 25, 26 and 27 are binary command, remote operated valves 31, 32 and 33. Power for the remote control of valves 31, 32 and 33 may be by means of electricity, pneumatics or hydraulics. In the preferred embodiment and for the purpose of this example, valves 31, 32 and 33 shall be described as electric solenoids.
Downstream of each valve 31, 32 and 33 are spray nozzles 35, 36 and 37, respectively. These nozzles emit a fan-spray pattern and are positioned above the plane of the fourdrinier pond at a height which corresponds to the angular spread of the spray fan and the desired impact velocity. The angular spread of the spray fan is also determinative of lateral spacing between CD adjacent spray stations, the spacing being such to provide an approximately one-half inch overlap of adjacent spray fans.
In the machine direction (MD), measured parallel with the running direction of the fourdrinier screen 12, the nozzles 35, 36 and 37 are angularly separated about the "Y" axis by approximately 10°. This arrangement places the discharge jet axis of nozzle 35 at approximately 70°, nozzle 36 to 60° and nozzle 37 at 50° of the table plane 14.
Axis "Y" is normally located approximately 1.5 to 4 feet down the table plane 14 from the slice 11 and represents the line of impact along which the jets of all nozzles will collide with the traveling fourdrinier pond 30.
On some stock, basis weight and machine combinations, however, the effective MD location range for positioning the "Y" axis may be extended substantially to accommodate other machine equipment in the immediate proximity of the slice. At least one instance has proven an effective location for the impact line at 6 feet down from the slice landing. More subjectively, the impact line must be located within the pond zone of the fourdrinier where the individual stock fibers are still sufficiently fluid and mobile as to tolerate displacement by the spray impact and subsequently reverse flow to level and smooth the boundaries of the channeled swath following the spray before such fibers are positionally set at the "dry line" end of the pond. This state of conditions more generally determinative of the impact line MD location is characterized as the fiber mobile zone of the pond.
For optimum flexibility as to total flow rate increment spacing, nozzles 35, 36 and 37 should be selected with different orifice sizes to issue relatively proportional flow rates and spray fan width under the same pressure drive. A representative orifice size distribution among three nozzles under a 40 psi manifold pressure may be, for example, 1 gpm for nozzle 35, 2 gpm for nozzle 36 and 4 gpm for nozzle 37, the proportionality being:
F.sub.n =2.sup.n-x
where:
F n =flow rate available from nozzle n
x=flow rate sizing factor which differs between particular nozzles of a respective station by a unit quantity
n=unit number identity of a particular nozzle in a spray station sub-system
As an operative example of the foregoing relation, assume a spray station having 3 nozzles and a sizing factor of 1. For the first nozzle, n=1 and x=1. Accordingly, F 1 =2 0 =1. For the second nozzle, n=2 and x=1, therefore F 2 =2 1 =2. For the third nozzle, n=3 and x=1 so F 3 =2 2 =4.
Manifold 21 is sized and provided with a fluid supply of such capacity as to maintain the desired line pressure throughout the full span of expected flow rate demanded by the spray system. Depending on the desired basis weight of the web being laid, the pressure within manifold 21 may range from 20 to 100 psi. For most applications however, a 40 to 60 psi pressure range is more appropriate for a 33 pounds per ream web basis weight target moving at a screen speed of 1335 fpm to deliver a water spray into impact with the pond at 77 fps velocity. The total fluid flow rate delivered under such conditions will vary with the machine speed, the basis weight target and the magnitude of localized fiber concentration being treated. However, regardless of total hydraulic power delivered to the web, the spray impact velocity should preferably be in the range of 70 to 100 fps to generate the necessary fiber fluidizing shock disturbance.
Control over the many binary command valves 31, 32 and 33 necessary for a large, 260 inch deckle width papermachine may be conveniently asserted by means of a command station which comprises a panel array 41 of rotary thumbwheel switches 42a, 42b, 42c, etc. such as that shown in FIG. 1. The single line control circuits 43a, 43b, 43c, etc. to the valves 31, 32 and 33 of a respective spray station 20a, 20b, 20c, etc. in fact, each represent three conduits 51, 52 and 53 respective to valves 31, 32 and 33 as illustrated by FIG. 3.
The typical schematic of FIG. 3 shows switch 42 to be interposed in the circuit continuity between a spray station 20 and a power source 100. Conductor 90 connects the power source to a conductive hub 63. A non-conductive thumbwheel disc 60 is secured to the hub 63. Also secured to the disc 60 are radial conductors 65 and contact points 62 in continuity with the hub 63 and journal 64.
Around the periphery of disc 60 are eight thumb lobes 61 uniquely identified by indicia 66. In this example, the indicia also state the total fluid flow rate in gpm units applied to the web pond 30 from the respective spray station 20.
Stationary brush contacts 54, 55 and 56 are respectively connected via conduits 51, 52 and 53 to the solenoid actuators of valves 31, 32 and 33. Relative to the reference position shown on the drawing opposite from disc lobe "0", there are no power transmissive contact points 62. Consequently, when the disc 60 is placed in this angular alignment relative to the reference position, none of the valves 31, 32 and 33 will be energized. Assuming an "energized-on" type of valve operation, fluid flow to all nozzles 35, 36 and 37 will be blocked.
When the disc 60 is rotated about the axis of journal 63 to an angular position that aligns disc lob "1" with the reference position, the contact point 62 in radial alignment with the lobe "1" will contact brush 54 to energize valve 31 thereby issuing fluid spray from nozzle 35 which applies one gpm of fluid to the pond 30 under the selected spray station 20.
Since the disc lobe position "1" provides no other contacts 62 along this particular radius, valves 32 and 33 will remain de-energized.
When the foregoing principle is applied to the six other angular positions of disc lobes 61 and the corresponding radial positionment of contacts 62 relative to brushes 54, 55 and 56, it will be seen that each angular position commands a respectively unique total fluid flow rate from the three valve combination of each spray station 20. In this manner, greater fluid flow rates may be applied to the pond 30 by those spray stations 20 at the center of a fiber concentration streak; the flow rates from spray stations located laterally of the concentration center being graduated down as illustrated by the switch 42 settings on panel 41 of FIG. 1. Additionally, such flow rate graduations may be achieved at substantially the same impact velocity from all operative nozzles so long as the single supply manifold 21 carries sufficient pressure to maintain a critical pressure differential.
The end result of the invention on the web pond 30 is that a streak of heavy fiber concentration, as detected by a basis weight scanning sensor 16, for example, and reported by an appropriately calibrated and referenced oscilloscope 17, may be uniformly distributed over the entire web CD. The impact shock of the spray stream fluidizes the fiber concentration while the laterally graduated flow rate provides a laterally flowing fluid vehicle to carry and deposit such fiber where desired in appropriate concentrations.
As explained in greater detail by said U.S. Pat. No. 3,989,085, the fluid impacting principle described above relative to fiber and basis weight redistribution is also relevant to moisture concentrations. In such cases the condition profile sensor 16 is of a type well known to the art for detecting the proximate water mass, independent of fiber. The effective working fluid issued from the spray nozzles is air. In other words, if the single paper stock constituent to be redistributed is fiber, the appropriate working fluid is water. On the other hand, if the single stock constituent to be redistributed is water, independent of fiber, the appropriate working fluid is air.
For the purpose of teaching a preferred embodiment, operational control over the present invention has been described relative to a command station which comprises a panel array of rotary cascade switches 42. It should be understood, however, that numerous other switching techniques may be utilized with equal effectiveness. For example, each nozzle flow control valve 31, 32, or 33 may be provided with an independent single pole, single throw switch, the decision of which switch to close for a desired flow rate combination being left to the operator.
Having fully and completely described my invention, | The characteristic profile of a paper web is adjusted on the fourdrinier by means of a number of fluid spray stations positioned across the papermachine. Each spray station is provided with two or more fan spray nozzles of different flow capacity oriented to impact the pond with fluid along a common line. Flow to each nozzle is binary controlled with respective binary command, full flow valves. By discrete manipulation of valve selection, total flow rate to the web may be adjusted without flow throttling and consequent impact velocity variations. | 3 |
FIELD OF THE INVENTION
The invention relates generally to the field of electronics and, more particularly, to supplying power to electronics equipment.
BACKGROUND OF THE INVENTION
In a computerized electronic system, which includes multiple electronics modules, a backplane is used in order to provide primary power to the modules, as well as to enable each of the modules to communicate with each other and with the external environment. As backplane communications technology progresses, fewer physical connections to the backplane are required since multiconductor parallel interfaces can be replaced by high-speed interfaces. Additionally, the use of high-speed fiber interconnections further reduces the required complexity of the backplane since each of the electronics modules can communicate with each other and with the external environment using only a single fiber-optic interface.
However, although electronics modules need only communicate using a single fiber optic connection, thus virtually eliminating the need for a conventional backplane, a need still exists to provide primary power to the electronics module. Hence, an apparatus for coupling power to an electronics module, which does not require a conventional backplane, would be highly desirable.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is pointed out with particularity in the appended claims. However, a more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the figures, wherein like reference numbers refer to similar items throughout the figures, and:
FIG. 1 is a block diagram of an electronics module, which includes provisions for receiving primary power in accordance with a preferred embodiment of the invention;
FIG. 2 is a top view of a card guide for coupling power to the electronics module of FIG. 1 in accordance with a preferred embodiment of the invention;
FIG. 3 is an isometric view of a portion of the card guide of FIG. 2 which includes provisions for coupling power to an electronics module in accordance with a preferred embodiment of the invention;
FIG. 4 is an isometric view of an apparatus for coupling power to multiple electronics modules in accordance with a preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An apparatus for coupling power to an electronics module eliminates the need to use the backplane to bring primary power to the electronics module. According to one aspect of the invention, power is instead coupled through the lateral edge portion of the electronics module through the use of power-coupling pads located on the electronics module and power supply clips located within the channel of the card guide. By using the lateral edge portion of the electronics module, the length of any board traces on the electronics module can be reduced, thus reducing the level of electromagnetic interference caused by long lead lengths of current-carrying conductors. Additionally, through the use of substantially planar coupling pads located on the module and the power supply clip located in the card guide, a less resistive primary power-coupling path can be achieved.
FIG. 1 is a block diagram of an electronics module which includes provisions for receiving primary power in accordance with a preferred embodiment of the invention. In FIG. 1, electronics module 100 includes electronic components 110 , 120 , 130 , 140 , and 150 . These electronic components can be and type of computer electronics components such as central processing units, memory elements, bus interfaces, and related equipment. Each of these electronic components receives primary power from at least one of power-coupling pads 160 and 170 using board traces 165 , 175 , and 185 . Electronic components 110 , 120 , 130 , 140 , and 150 may communicate with each other using board traces other than those shown. This additional coupling paths can include address lines, control lines, data buses and hardware interrupts. Data connectors, such as those used for fiber optic interfaces, have not been shown for simplicity.
As an example, which is not intended to limit the scope of the invention, power-coupling pad 160 can be intended to convey a primary power voltage of 5 Volts to each of electronic components 110 , 120 , and 130 . Continuing with this example, power-coupling pad 170 may be intended to convey a voltage of 12 Volts to electronic components 140 , 150 , and 110 , where electronic component 110 requires dual voltage inputs of 5 and 12 Volts.
Power-coupling pads 160 and 170 are preferably located at lateral edge portion 105 of electronics module 100 within an area, which contacts a card guide when the module is inserted. In the example of FIG. 1, power-coupling pad 160 is located a distance L 1 from the lateral edge portion of electronics module 100 and a distance of L 4 from front edge 107 of the electronics module. Further in accordance with the example of FIG. 1, power-coupling pad 170 is located a distance L 2 from the lateral edge portion of electronics module 100 , and a distance L 5 from front edge 107 of the electronics module. Additionally, power-coupling pads 160 and 170 are separated by a lateral distance of L 3 .
It should be noted that the use of power-coupling pads 160 and 170 has on a lateral edge portion of electronics module 100 allows a greater degree of freedom in the placement of electronic components 110 , 120 , 130 , 140 , and 150 . In the event that one or more of these electronics components requires a large current to operate the component, the particular component need not be placed near front edge 107 in order to reduce resistive losses. Rather, the high current component can be placed along the length of lateral edge portion 105 , thereby allowing a reduction in the associated board trace, which conveys the power to the device, such as board traces 165 , 175 , and 185 . This can be useful in reducing the amount of radiated electromagnetic interference caused by high current signals conveyed through long board traces.
Power-coupling pads 160 and 170 can be comprised of a metal such as gold, palladium, nickel, chromium, lead or other suitable metal, which possesses high conductivity, as well as a degree of resistance to corrosion. Additionally, it is desirable that the metal selected for use by power-coupling pad 160 and 170 be sufficiently durable so as not to be easily abraded as a result of repeated insertion and removal of electronics module 100 into and out of the card guide of FIG. 2 . Further, power-coupling pads 160 and 170 are desirably separated by an amount equal to L 3 . This separation precludes the possibility of shorting together two power supply clips (as described in reference to FIG. 2) during insertion and removal of electronics module 100 . The possibility of shorting two power supply clips together can be further reduced by placing coupling pads 160 and 170 on both the first and second sides of electronics module 100 .
FIG. 2 is a top view of a card guide for coupling power to the electronics module of FIG. 1 ( 100 ) in accordance with a preferred embodiment of the invention. In FIG. 2, card entrance 220 is intended to receive a lateral edge portion of electronics module 100 as the electronics module is slid into the card guide of FIG. 2 towards front edge 207 portions. Preferably, the card guide of FIG. 2 operates mechanically in a manner similar to conventional card guides by retaining and supporting the electronics module as the module is wedged between first half 200 and second half 210 . A second card guide which incorporates the conventional electronics module support and retention features of the card guide of FIG. 2 is preferably mechanically interfaced to the opposite lateral edge portion of electronics module 100 in order to support the electronics module from both the top and bottom.
When electronics module 100 is inserted into the card guide of FIG. 2, power-coupling pad 170 preferably makes contact with power supply clip 240 . Similarly, power-coupling pad 160 makes contact with power supply clip 250 . Power supply clips 240 and 250 are preferably located a distance L 4 and L 5 , respectively, from front edge 207 portion of the card guide of FIG. 2 . Additionally, although not shown in the two-dimensional view of FIG. 2, power supply clip 240 is offset a distance L 2 from the deepest portion of the channel of the card guide of FIG. 2 in order to mate with power-coupling pad 170 . In a similar manner, power supply clip 250 is offset a distance L 1 from the deepest portion of the card guide in order to mate with power-coupling pad 160 .
FIG. 3 is an isometric view of a portion of the card guide of FIG. 2 which includes provisions for coupling power to an electronics module in accordance with a preferred embodiment of the invention. In FIG. 3, the arrangement of power supply clips 240 and 250 within the card guide of FIG. 2 can be more easily seen. As previously mentioned in reference to FIG. 2, power supply clip 240 is offset by an amount of L 2 from the deepest portion of the card guide. In a similar manner, power supply clip 250 is offset from the deepest portion of the card guide by an amount of L 1 . In order to maintain continuous and positive contact with power-coupling pads 170 and 160 of electronics module 100 , first half 200 of the card guide of FIG. 2 preferably includes a spring or other resilient element which possesses the capability recover its shape after deformation. Additionally, although shown as rectangular in nature, power supply clips 240 and 250 as well as power coupling pads 160 and 170 need not be in accordance with this shape. According to the needs of the particular application, the power supply clips and power-coupling pads may assume various other shapes such as circles, ellipses, or other suitable geometries.
Although FIGS. 1-3 indicate the use of power-coupling pads and power supply clips located only on a first side of an electronics module and on a corresponding first half of a card guide, nothing prevents the use of power coupling pads on the reverse side of electronics module 100 . In a similar manner, nothing precludes the use of a power supply clip located on the opposite side of the card guide of FIG. 2 .
FIG. 4 is an isometric view of an apparatus for coupling power to multiple electronics modules in accordance with a preferred embodiment of the invention. In FIG. 4, primary power bus 440 conveys power to electronics modules 100 and 400 by way of primary power-coupling lines 450 and 460 , respectively. In a similar manner, primary power bus 445 conveys power to electronics modules 100 by way of primary power-coupling line 470 . The use of separate primary power buses in FIG. 4 allows distinct voltages to be conveyed to each of electronics modules 100 and 400 . Thus, primary power bus 440 can convey 12 volts to electronics modules 100 and 400 , while primary power bus 445 conveys 5 V primary power to the electronics module 100 . Although the technique of power-coupling is shown as requiring wire loops, the present invention does not require this. Other conventional techniques of coupling power to the electronics modules may be used.
An apparatus for coupling power to an electronics module eliminates the need to use the backplane to bring primary power to the electronics module. The resulting system provides additional freedom by allowing board designers to locate high current and electromagnetic field-generating components near power-coupling pads, thus reducing resistive losses and electromagnetic fields caused by longer board traces. Additionally, through the use of substantially planar coupling pads located on the module and the power supply clip located in the card guide, a less resistive primary power coupling path can be achieved.
Accordingly, it is intended by the appended claims to cover all modifications of the invention that fall within the true scope and spirit of the invention. | A power-coupling pad (FIG. 1, 160 or 170 ) is located on a lateral edge portion of an electronics module ( 100 ). Each power-coupling pad ( 160, 170 ) is mated with a power supply clip (FIG. 2, 240, 250 ) which is included within a side of a card guide that supports and retains the electronics module ( 100 ). The power supply clip ( 240, 250 ) can incorporate a spring which provides constant and affirmative contact with the power-coupling pad ( 160, 170 ) through a low resistance path. The power-coupling pad ( 160, 170 ) and power supply clip ( 240, 250 ) can be constructed using any suitable conductive material such as gold, nickel, lead, chromium and palladium. | 7 |
BACKGROUND OF THE INVENTION
This invention relates, in general, to power dividers and combiners used in microwave systems, and more particularly, to wide-band power dividers and combiners which can be incorporated on a single miniature integrated circuit (I.C.) chip.
Powder dividers are used to take a signal at a common terminal and divide the signal among a series of signal paths while maintaining desired impedances at the common terminal and at all output terminals. The same apparatus can be used as a power combiner by feeding signals to each of the signal paths and combining these signals at the common terminal.
Conventional power dividers generally utilize quarter-wave transmission lines in their signal paths. These dividers are often referred to as Wilkinson power dividers since they incorporate isolated, branch waveguide power dividers as disclosed in U.S. Pat. No. 3,091,743 to Wilkinson. Wilkinson power dividers have good isolation between their output terminals. The bandwidth of Wilkinson power dividers is increased by cascading additional sections of the power divider, each section incorporating a quaterwave length transmission line. A correlation between bandwidth ratio and number of sections incorporating quarterwave length transmission lines is given in the following table which was developed by Seymor B. Cohn in "A Class of Broadband Three-Port TEM-Mode Hybrids", IEEE Transactions on Microwave Theory and Techniques, Vol. MTT-16, No. 2, February 1968.
TABLE 1______________________________________Sections 2 3 4 7______________________________________Bandwidth Ratio 2.0 3.0 4.0 10.0(x:1)______________________________________
Thus, as the bandwidth increases, the size of the divider increases. Because of the increasing size of the divider with increasing bandwidth, Wilkinson type dividers with large bandwidths cannot readily be miniaturized to fit on a single chip.
Recent developments in technology have allowed the size of many electronic components to be reduced. The size of products using these components are undesirably increased if large dividers must be included therein. Hence, broadband Wilkinson dividers have become impractical for miniature applications. Some power dividers have been designed which replace transmission lines with discrete lumped element components. However, these have not had the bandwidth associated with cascaded Wilkinson dividers, and in fact, are limited to very narrow bandwidths. The prior art, therefore, has not provided a power divider with a broad bandwidth which can be miniaturized to fit on a single I.C. chip.
SUMMARY OF THE INVENTION
A wide-band microwave power divider/combiner is provided in accordance with this invention which can be miniaturized to fit on a single chip. To increase the bandwidth while maintaining good isolation performance, the invention contemplates coupling low pass filters and high pass filters in series along a plurality of signal paths and connecting the signal paths with isolation resistors. These filters comprise discrete components. By using discrete components, the entire wide-band power divider can be incorporated on a single I.C. chip.
It is, therefore, an object of the present invention to provide a wide-band microwave power divider/combiner.
Another object of the present invention is to miniaturize the power divider/combiner.
A further object of the present invention is to allow the power divider/combiner to be constructed in I.C. form.
Other objects and advantages of the present invention will become apparent from the following detailed description, particularly when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block schematic diagram of a miniature wide-band microwave power divider in accordance with the present invention.
FIG. 2 is a schematic diagram of a circuit for a miniature wide-band microwave power divider in its preferred embodiment in accordance with the present invention.
FIG. 3 is a schematic diagram of a multi-section prior art Wilkinson power divider.
FIG. 4 is a chart showing performance characteristics for a miniature microwave power divider in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A miniature wide-band microwave power divider 10, in its preferred embodiment and as diagrammed in the block schematic of FIG. 1, comprises a common input terminal 12, a plurality of parallel signal paths 14 and 16, and a plurality of output terminals 18 and 20. Signal path 14 comprises low pass filter 22 and high pass filter 24 and signal path 16 comprises low pass filter 23 and high pass filter 25. Signal path 14 is coupled to signal path 16 by low pass resistor 26 immediately after low pass filter 22, and high pass resistor 28 couples signal path 14 to signal path 16 immediately after high pass filter 24.
Within the industry, this apparatus is known as a "power divider" because it divides an input signal received at common terminal 12 between signal paths 14 and 16. The divided signals are then fed to outside loads through output terminals 18 and 20. This same type of structure acts to combine signals by feeding the signals through output terminals 18 and 20 and out through common terminal 12. In the industry, this is known as a "power combiner".
Low pass filter 22, in its preferred embodiment as shown in FIG. 2, comprises a low pass inductance 30 and low pass capacitance 32 arranged in a "tee" configuration with low pass capacitance 32 connected to ground. In the "tee" configuration, low pass inductance 30 comprises two discrete inductor components and low pass capacitance 32 comprises one discrete capacitor component. One with ordinary skill in the art will recognize that low pass filter 22 may be constructed in other configurations such as a "pi" configuration comprising one discrete inductor component and two discrete capacitor components. In one embodiment, low pass capacitance 32 has a value of 0.11 picoFarads (pF) and low pass inductance 30 has a value of 0.84 henrys (H).
High pass filter 24, in its preferred embodiment, comprises high pass capacitance 34 and high pass inductance 36 arranged in a "tee" configuration with high pass inductance 36 connected to ground. High pass capacitance 34 comprises two discrete capacitor components and high pass inductance 36 comprises one discrete inductor component. As with low pass filter 22, high pass filter 24 may be constructed in other configurations such as a "pi" configuration. In one embodiment, high pass capacitance 34 has a preferred value of 0.5 pF and high pass inductance 36 has a preferred value of 1.5 H.
Low pass resistor 26 and high pass resistor 28 operate to isolate signal paths 14 and 16. In one embodiment, low pass resistor 26 is 100 ohms and high pass resistor 28 is 250 ohms.
In operation, assuming a 6 GH z lower cutoff frequency, high pass filter 24 provides impedance transformation and a 90° phase shift. Assuming an 18 GH z higher cutoff frequency, low pass filter 22 provides impedance transformation and the necessary 90° phase shift.
FIG. 4 shows frequency in Gigahertz (GH z ) along abscissa axis 43 and divider performance in decibels (db) along ordinate axis 45. Insertion loss (IL) performance curve 42 of FIG. 4 indicates an optimum frequency, between 6 and 18 GHz, for power divider 10 of FIG. 1. Within the bandwidth, input return loss (IR) of common terminal 12, shown by IR curve 44, output return loss (OR) of output terminals 18 and 20, shown by OR curve 46, and isolation between output terminals 18 and 20 shown by isolation curve 48, exhibit good performance.
By combining low pass filter 22 and high pass filter 24 in series, a relatively wide-band frequency range is obtained. The combination of low pass filter 22 and high pass filter 24 in power divider 10 yields substantially the same bandwidth as a 3-section cascaded Wilkinson-type transmission line power divider as shown in FIG. 3.
Power divider 10 is constructed entirely on a miniature chip due to use of discrete components in low pass filter 22 and high pass filter 24. Conversely, a Wilkinson-type transmission line power divider requires substantially more area than is available on a miniature chip due to the multi-lengths of transmission line. Although some isolation performance is given up as compared to the large prior art Wilkinson dividers to miniaturize power divider 10, power divider 10 still operates within a good performance range and is adequate for many applications.
Although a preferred embodiment of power divider 10 has been shown as having two parallel signal paths 14 and 16, it is contemplated within the scope of the present invention that power divider 10 may be used as an N-way power divider with N being a whole number greater than one. The difference between a two-way divider and an N-way divider with 3 or more signal paths is the design of the discrete components to obtain a consistent impedance transformation. In order for 50 ohms to be present at all ports (common terminal 12 and output terminals 18 and 20) of a two-way power divider, an impedance transformation from 100 ohms to 50 ohms is needed in each signal path. For 50 ohms to be present at all ports of an N-way power divider, the impedance transformation would be from (N×50) ohms to 50 ohms and the discrete components of low pass filter 22 and high pass filter 24 would be designed accordingly.
Thus, a miniature, wide-band microwave power divider with low pass filters and high pass filters incorporating discrete components has been described herein. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the appended claims. | A miniature wide-band microwave power divider comprising a common terminal connected to a plurality of parallel signal paths with each signal path comprising a low pass and a high pass filter made up of discrete components. Use of discrete components allows the entire power divider to be incorporated on a single chip. Isolation is achieved between the signal paths by isolation means comprising resistors. | 7 |
The present invention claims priority under 35 USC 119(e) to U.S. Patent Application No. 60/959,395, entitled OPEN API DIGITAL VIDEO RECORDER AND METHOD OF MAKING AND USING SAME filed Jul. 13, 2007, with inventors Chad Steelberg and Ryan Steelberg, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention is directed to application software and, more particularly, to an open-API digital video recorder and a method of making and using same.
SUMMARY OF THE INVENTION
A digital video recorder is disclosed. The digital video recorder includes at least one memory device, a plurality of communication access points for receiving at least one program play, an open application programming interface associated with the at least one memory device, and at least one correlation engine in communication with the open application programming interface. The plurality of applications correspondent to the open application programming interface allow a user to manipulate metadata associated with ones of the programs plays and the metadata relates to interframe interactivity with detailed aspects of the ones of the program plays. The at least one correlation engine provides for correlation among at least for the interframes of the program play to ones of the interframes of other ones of the program plays, and among the interframe interactivity to the interframes of the program play to interframe interactivity with the other ones of the interframes of the other ones of the program plays.
BRIEF DESCRIPTION OF THE FIGURES
The present invention will be described hereinbelow in conjunction with the following figures, in which like numerals represent like items, and wherein:
FIG. 1 is a block diagram illustrating a home having resident therein at least one television set having associated therewith at least one digital video recording unit;
FIG. 2 illustrates a video which will be displayed to the user as a program play; and,
FIG. 3 is an example illustrating certain applications and/or filters interacting with the message bus and having associated therewith core applications, and may be surrounded by metatags in a manner similar to the base video of interest.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for the purposes of clarity, many other elements found in typical interactive and application programming interface (API) systems and methods. Those of ordinary skill in the art will recognize that other elements are desirable and/or required in order to implement the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
FIG. 1 is a block diagram illustrating a home having resident therein at least one television set having associated therewith at least one digital video recording unit (hereinafter “DVR”). As defined herein, a DVR preferably includes at least one memory unit, such as a hard drive, RAM, flash memory, or the like, at least one communication access point, the capability to read metadata received via one of the communication access points, and the capability to write metadata related to a user's use of the DVR. Such communication access points may include one or more of, for example, satellite communication, coaxial cable communication, WiFi communication, WiMax communication (such as Sprint/Nextel, Tier 1, and Clearwire, Tier 3), other wireless LAN (local area network) communication, telephonic or DSL communication, T-111 or Ethernet communication, or the like. Further, the DVR preferably includes an operating environment that has associated therewith at least one application program interface (API). The at least one API allows for a programmer to write applications consistent with the operating environment. The API preferably includes a set of routines, protocols, and/or tools to allow for programmers to create software applications consistent with the operating environment, as will be apparent to those of ordinary skill in the art. Programs consistent with the API may be pushed or pulled to or by the DVR over the one or more communication access points in response to or as a command to the operating environment.
The DVR of the present invention may thus have accessible thereto a plurality of communication media types, including, but not limited to, cable television channels, satellite television channels, the worldwide web, email capabilities, data (including video and audio) libraries, and the like, each of which communication media types may form the basis for the creation of a “program play,” in which one or more programs (audio or video) are presented to a user. In prior embodiments, television programs that play through the DVR have associated therewith a limited amount of metadata that is indicative only of “thematic”, principally outerclip aspects of the television program, such as time of the program play, length of the program play, title of the program play, description of program play and significant actors or actresses associated with the program of the program play. The limited metadata associated with the program play received over one or more of the respective communication access points is then made available, in the prior art, for limited manipulation by the user with regard only to those aspects of the program play with which the thematic metadata is associated. Because the API of prior art DVR technology is closed, programmers are not universally afforded the opportunity to make greater use of information in any respective program play.
The present invention provides, via an open API DVR, an accessibility by the DVR to program plays or applications over any of a plurality of communication access point types mentioned hereinabove, as well as to play program plays of any communication media type as also mentioned hereinabove. As such, a myriad of applications may be written by programmers for operation on or in any of the variety of communication media, and for operation over nearly any communication access point type, and such applications may be pushed, pulled, or accessible over any of the aforementioned communication access points. Further, such application may allow for pushing or pulling for numerous interactivity types, including server interactivity, peer interactivity (including point-to-point sharing), and program play feed interactivity, for example. Such interactivity may be via an accessing of exposed application hooks to the aforementioned metadata.
Such applications written for the open API of the present invention may provide improved interactivity by, for example, exposing via the application metadata associated with each and every aspect of the program play on any given communication media. For example, metadata may be associated with each word spoken, sound made, and picture shown in any given program play, such as a television or radio program, and as such programmers may expose via the open API information not merely contained within or directly associated with the program play, but that is rather associated with the metadata associated with the program play. The metadata employed in the present invention is discussed further hereinbelow with respect to FIGS. 2 and 3 . The metadata may be made accessible to the user via, for example, application software in the form of a program play overlay, in which an overlay-user interface is placed at the forefront of the program play currently in view of the user, which program play is a television program in the example immediately hereinabove. Such an overlay may take the form of, for example, an overlay that provides links, dropdown menus, windows, or other readily accessible user interfaces. Further, it will be evident to those of ordinary skill in the art that applications may be written that provide multiple windows, menus, or the like simultaneously to a single user, wherein each window plays over a television interface and provides a different program play, and consequently a different overlay, to the user, thereby providing an enhanced version of the known “picture in picture” program plays.
As mentioned hereinabove, the metadata associated with a particular program play of a particular communication media may allow for a “hook” to accessibility of any aspect of the program play, including, but not limited to, externally accessible media, such as other program plays starring the same actor, other program plays starring the same musician, advertising related to goods illustrated in the program play, purchasing points for goods illustrated in the program play, external information, such as World Wide Web (www or Web) information regarding items illustrated in the program play, and the like. Such external information may be accessible via a user activation of aspects of an overlay on the program play, or the accessing of certain aspects of an overlay or the program play itself may lead the user to menus, windows, or the like outside the program play, and the desired information may be accessible from such menus, windows, or the like.
In an exemplary embodiment of the present invention, the open API DVR may allow for an application having an eBay® overlay to be placed on a particular television show, such as “The Antiques Roadshow”, and the user may thereby access, via the overlay, similar items available on eBay® to those items being illustrated in the show. Alternatively, rather than the eBay® overlay being placed upon The Antiques Roadshow (the program play of the communication media television), which is received by the DVR via the communication access point cable or satellite, eBay®, an affiliate, or a third party programmer may create a unique channel for reception by the DVR over a different communication access point, which eBay channel shows still photographs, videos, audio, or the like, that relate to items of frequent interest to buyers of eBay® goods, and the eBay® overlay may be placed thereover to allow a user to access further information with regard to those goods or access points of purchase, such as by moving the user to the World Wide Web upon activation by the user of aspects of the overlay. As such, eBay® may create its own unique communications media channel for display over television and may send this new channel for communication to the DVR via WiMax or the like, and as such new “television channels” can be created for access via communication access points not generally used currently by televisions.
In an additional exemplary embodiment, a user may be viewing a highly fashion-related program play, such as Desperate Housewives on ABC, in which different fashions or accessories are highly prevalent. If all such information associated with that program play is metatagged, the user may access information on the fashions being worn, or the accessories being used, and such information may include accessibility to other external information, such as comments from fashion editors, available purchase points of the items of interest, and external payment sites to allow for the purchase of those items of interest.
In an additional exemplary embodiment, a user may enter, to an application pulled to the DVR via the open API, a list of that user's fantasy sports players. The present invention may make available to that user a menu listing those fantasy sports players, and the location at which those fantasy sports players may be watched, recorded, or auto-recorded, on any communication media via any communication access point, in real time. Additionally, certain players may be highlighted, such as when that particular player's team possesses the ball, so that the user may switch between communication media or communication access points to, in a targeted manner, allow that user to watch, record, or auto-record that user's players. Additionally and alternatively with regard to this exemplary embodiment, an application may allow the user to open multiple windows to watch multiple of that user's players in real time, and may maintain in each window an overlay, or may display in a separate window the menu of fantasy players, or may allow the user to toggle between the menu and the video or audio of the games being played.
Thus, for example, a user may select what events certain actions by the DVR are to trigger on, such as autorecording certain events, such as each time a football running back entered into the fantasy football menu interface scores a touchdown. As such, a user can create his or her favorite, or most frequently accessed, metatags, and the metatags may be placed on all content, and on the user's accessing of all content.
In a broader sense, these exemplary embodiments illustrate that one or more applications pulled or pushed via the open API to the DVR may allow the user to assess, in real time, and/or watch, or auto-record, multiple programs, portions of programs, snippets, ads, or the like of interest, inside or outside of any program play (such as via a selectable toolbar generated in accordance with a unique application), use multiple windows of interest simultaneously, be presented with multiple overlays of interest, be presented with multiple menus of interest, all of which may allow the user to access multiple pieces of information or external information not currently available to the user via a television program play. Further for example, as discussed hereinabove, the user may use any application, such as a software overlay, while watching a football game for example, to access any information related to all or any portion of that program play, such as information on the types of shoes worn by that user's favorite player, where the user may buy the jersey worn by that user's favorite player, may access an online purchase point for those shoes or that jersey, and/or may pay using an on-line point of payment account, such as PayPal, all from the DVR of the present invention.
As such, the present invention may also provide a highly targeted marketing tool for advertisers, in that each user will access information of interest to that particular user, thereby ensuring that an advertiser's advertisement is played to a user that is most interested in the item being sold. Thereby, advertisers will have less need to place ads in program plays in which 99% of the viewers of the program play are not interested in the item being sold. Further, the present invention will allow such commerce interaction by each user to be uniquely tracked.
Not only will the addition of metadata add more targeted marketing opportunities, such as to make television ads into drill downs rather than just thirty second videos, but additionally the addition of metadata will allow “add-on programming” associated with television shows, which is presently found on line on the Web, to be brought back to the television media. For example, on line universes that are created for association with shows on television may, via metadata, menus, and/or overlays that access the metadata, allow for those on-line universes to be brought back on to television.
Further, the applications written for the DVR are of the present invention may, as do present DVR's, collect metadata on use by the user of the DVR, as mentioned hereinabove. Without violation of privacy laws, such information may, using the applications for the open API discussed herein, be passed to third parties and the metadata may be collected, thereby allowing third parties to generate yet more targeted advertising, more targeted programs plays, and more communication media (such as communication channels) of interest to the highest number of users.
In light of that discussed hereinabove, the open API of the DVR of the present invention may provide hooks into all items of interest and into the operating environment of the DVR, and the exposure of those hooks via the open API will allow third parties to tie into those hooks. Further, users can access applications associated with those hooks via the metadata tags associated with those hooks. Such metadata tags may allow, for example, applications that make use of overlays, video overlays, water marking, auto pause, auto record, toolbars, menus, and the like. The applications so generated may be locally processed on the DVR (such as for certified applications), or can be streamed to the DVR, or can be associated with entirely new, externally generated communication channels. Additionally, as discussed hereinabove, although the DVR may have associated therewith some local storage, vast quantities of remote storage may be made available, such as at external sites accessible via WiMax or the like. As such, a user may be charged for any level of desired storage for programming, and will not be limited for storage by the hardware of the DVR resident within the user's home.
Thus, the present invention may make available any of a variety of communication channels, and any of a variety of applications for accessing metatags associated with the communication media being played on any of those communication channels. For example, a real estate channel may be made available, and the real estate available on the real estate channel may be targeted to the preferences entered by the user of interest. Alternatively, a completely interactive gaming channel may be made available wherein trivia games, casino games, or the like may be made available in accordance with user preferences, and actions undertaken by the user may be received by the DVR as metadata that may be made available to third parties. Alternatively, complex interfaces may be made available via a metadata feed. For example, a user may watch a nature show on the Discovery Channel, and may hear or see mention of an animal of interest to that user. The user may then access, such as via an overlay, a link associated with that animal of interest. That link may provide the user with access to, for example, Google Earth, which may allow for illustration to the user of all animals of that type, anywhere in the world, that have been tagged and placed back into the wild and that are open to sponsorship by a user. The user may be then given the option to sponsor one of the animals in a location of interest to the user, and in the event the user selects an animal to sponsor, an on-line payment interface, such as PayPal, may be accessible to the user for payment of the sponsorship fee. Alternatively, either within the program play on the Discovery Channel, or after drilling down to the animal of interest, the user may be presented with a mention of a country of interest to the user, such as Botswana. The user may pause, and either exit the program play via the overlay, or may exit the Google Earth interface displaying the animals of interest, and may redirect to find information, such as on Wikipedia, on “Botswana.” After the user has redirected a sufficient number of times to receive the information of interest to the user with regard to Botswana, the user may elect to be redirected back to the initial location of interest, which in this example is either the program play or the information on the animal of interest.
The present invention may also include social networking. Such social networking may include videoconferencing, video messaging, or placement of personal information or personal ads on line, or placement of video or audio generated by a user that the user would like to make accessible to third parties, from the communication access points accessible to the user via the open API DVR, thus making the user “the star of” his or her own show.
The present invention may additionally include, for example, a mobile DVR, wherein DVR features accessed via mobile televisions, televisions not within the home residence, navigation screens within vehicles, or the like, accessible to any of the aforementioned communication access points, and such mobile DVR may communication with the home, open API DVR.
More specifically with regard to the above-referenced metatagging, the metatagging of the present invention is typically to take place interclip, and may be thematically or non-thematically related. More specifically, the tagging may be done interclip and interframe, and/or frame-by-frame, and may relate to words, pictures, and the like that occur within the frame, whether or not related to the thematic nature of the programming. Such tags may be associated with the interframe programming by, for example, the automatic nature of the application then running, may be inserted remotely at the programming for the programming displayed, or may inserted by the users as the programming is viewed. Further, such tagging allows for actions to be taken on discrete portions of an overall program play, unlike the actions made available by the prior art. Additionally, such metatags may be streamed in-content, or in a separate metastream tied to the program play, as discussed with particularity immediately hereinbelow.
As will be apparent to those skilled in the art, a metatag as used herein is a computer-readable language, such as xml, html, or the like, syntax statement that may be sent along with a program play, such as by being sent as a secondary stream fed to a user along with a streamed program play, or that may be sent as part of a program play, such as in the “header” information that describes the computing characteristics of the program play. The metatag may convey information about that with which it is associated (i.e. the program play in this example), and such information may or may not actually be found within such a program play. For example, such metatags may be hooks, such as for user commands, or may make requests of the user, or may be used as keywords in searching of program plays or program play portions. Each such metatag must be given a unique name, or tag, and have associated therewith unique content. Such association of keywords and content may be done automatically, such as by an automated search of a document, such as a script of a program play, or such as by spider searching, or such as by index searching, or may be done manually.
Further, metatags included within frames may be linked and/or correlated to other metatags, within or outside of the program then within view. For example, correlation may be performed from metatag to metatag, in frame, or from metatag to metatag from a frame of one program play to a frame in a separate program play, or from metatag to content stream, for example. Alternatively, correlation of metatag to metatag may occur from a frame within one program play to another frame within the same program play, or interframe between program plays. Correlation may be employed using authoring standard techniques and/or languages, such as Synchronized Multimedia Integration Language (SMIL) or Microsoft Synchronized Accessible Media Interchange (SAMI), among others, which may be separate from, and in a different syntax than, the program play stream(s). Further or alternatively, correlation functions and correlation branching known to those skilled in the art of mathematics may be employed by the applications programmed into the open API of the present invention, with regard to each frame, or frame portion, of every program play accessible to the open API DVR.
In certain exemplary embodiments, watermarking techniques typically employed for embedding correlated audiovisual interaction information may be used to correlate frames, interframes, or program plays in the present invention, with or without modification to the typical metatag data stream or headers (see, e.g., “Stream Based Interactive Video Language Authoring using Correlated Audiovisual Watermarking,” Xu, et al., ICITA '05 Proceedings, IEEE). Further, as such, upon placement into or into association with the program play, inframe metatags may have correlated therewith not only aspects of inframes of other program plays, but additionally any of the number of functions to be performed by the respective applications discussed herein throughout.
The association of metatags to other metatags may, in fact, create “clickable video.” Clickable video provides true interactivity to a watcher of any program play that presents the video to the user. As such, for example, the user may pause the video and use display objects known to those skilled in the art, such as a mouse cursor, to interact with portions of the video, or may call up such an interactive cursor to interact with the video while the video is playing. Further, metatagging may allow for variations in the mouse cursor that correspond to those aspects of the video currently playing when the mouse cursor is brought up on the screen. For example, if a portion of the video includes an actor in the video drinking a can of Coke, the mouse cursor, if called during that portion of the video, might display as a miniature can of Coke.
Thus, once the metastream is defined, clickable video frames can be created, correlation to the same or other metastreams may be performed, and passive processing may be performed with third party API's. Such third party processing may include, for example, remote commands such as DVR commands, that may, for example, allow for the taping of certain snippets of interest within larger program shows.
The manner of metatagging used in the present invention may, for example, be any methodology of metatagging known to those skilled in the art. Further, a program play may be metatagged before initial broadcast, before rebroadcast, or during the streaming of a broadcast stream. As such, rights in such metatagging may be available and divisible by pre-initial broadcast, in-broadcast, and rebroadcast, for example.
The present invention may be hierarchically organized as shown in FIG. 2 . FIG. 2 illustrates, as the focal point of the present invention, a video which will be displayed to the user as a program play. The video is metatagged as shown, and the hierarchy outside, but associated with, the metatags may then communicate with and using the metatags via a message bus. Surrounding the message bus may be a variety of filters, and surrounding the filters may be a variety of applications. The applications may access any of a number of the filters, and both the applications and the filters may have accessible thereto the message bus. The message bus may make available a variety of operation commands for interaction with the metatags, and the metatags may provide interoperability of the commands with the video.
The filters may be mapped into a variety of commands made available in the message bus, and thus the filters may be of a variety of types. For example, filters may include key word filters, commerce-type filters, location filters, geolocation filters, correlation filters, insertion filters such as for secondary feeds, and social filters, programmatic publishing filters, automatic publishing filters, and the like. The mapping of user commands performed by the filters, and performed by the applications that run the filters, may cause the application of one filter type to be a causation for application of a filter of another type. As such, applications can likewise feed one another, such as wherein an application of one type, such as a search application, accesses an application of another type, such as a Wikipedia engine, whereby answers to a user inquiry into a search engine can be obtained.
Further, for example, one application and/or filter may allow the saving of certain aspects of a program based on the application of another application indicating that the user wishes to seek certain snippets associated with certain topics. Further, once such snippets are saved, yet another application may allow the shipment of the frames or snippets of interest, based on the metadata illustrating that such frames are of interest, between users, such as via email programs, internet mail or WiFi for example. Additionally, as mentioned hereinabove, the open API aspects of the DVR of the present invention may allow for programmatic publishing, wherein an application actively publishes certain metadata or certain information received into the programming via, for example, automatic publishing (wherein such publishing occurs passively).
In a more specific example illustrated in FIG. 3 , certain applications and/or filters interact with the message bus. As illustrated, the applications and/or filters may have associated therewith core applications, and may be surrounded by metatags in a manner similar to the base video of interest. In an exemplary embodiment, the metatags of the application into which the user expresses interest in the location of certain animals of the world may come from a mapping application, wherein interaction B, as shown, interacts with the message bus based on the interaction B from the user. The metatag reached by interaction B may be a geographic location within a program then within view of the user, and may lead to interaction A reaching out to make other assessments of the user's mapped location of interest. For example, a different application may then be accessed by the first application based on the correlation of interactions A and B, and this different application may assess a variety of different animals, available animal sponsorships, records of national disasters, phone books, flora, or the like, that are resident in that particular geographic location. Such information may then be fed back to the user via the message bus interface, or the interest from the user may simply be written to the external application, and may be tracked by the application programmer. As such, multiple applications may collaborate as between the applications, may correlate as between the applications, and may filter as between the applications, and such actions may occur automatically, via programmatic publishing, and/or may be based on certain permissions.
The filtering and applications of the present invention made available via the open API DVR interface may thus be dependent on the capability to create an instream metastream that is not necessarily thematically related to any of the programs shown to the user. Such an instream metastream may include a metastream associated with any instream programming, which may include not only the programming of interest but also advertising associated with, or accessible from, the programming of interest.
Although the invention has been described and pictured in a preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made by way of example, and that numerous changes in the details of construction and combination and arrangement of parts and steps may be made without departing from the spirit and scope of the invention. | A digital video recorder is disclosed. The digital video recorder includes at least one memory device, a plurality of communication access points for receiving at least one program play, an open application programming interface associated with the at least one memory device, and at least one correlation engine in communication with the open application programming interface. The plurality of applications correspondent to the open application programming interface allow a user to manipulate metadata associated with ones of the programs plays and the metadata relates to interframe interactivity with detailed aspects of the ones of the program plays. The at least one correlation engine provides for correlation among at least for the interframes of the program play to ones of the interframes of other ones of the program plays, and among the interframe interactivity to the interframes of the program play to interframe interactivity with the other ones of the interframes of the other ones of the program plays. | 7 |
BACKGROUND
[0001] This disclosure relates generally to wrist braces, and more particularly to assistive wrist braces.
[0002] Wrist braces are generally used as a medical device to prevent injuries to that area, Wrist braces may also be used as assistive training devices for certain sports. It is problematic when assistive devices have not been invented for certain sports
[0003] It would be useful to develop assistive training device for sports that do not have any, such as for Frisbee.
SUMMARY
[0004] One embodiment described herein is an apparatus comprising a sleeve configured to be adjustably mounted around the user's wrist, a platform configured to limit the rotational movement of the user's wrist, and a connection between the top of the sleeve and the bottom of the portion.
[0005] Another embodiment described herein is a method of obtaining the apparatus, adjusting the angle between the sleeve and platform of the apparatus, and mounting the device on the wrist of the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows the front view of the device
[0007] FIG. 2 shows the side view of the device
[0008] FIG. 3 is the side view of the device with the platform set at a different angle
[0009] FIG. 4 shows a side view of the device with the platform set at another angle
[0010] FIG. 5 shows the front view of the device with the second fastener method
[0011] FIG. 6 shows the top view of the device
[0012] FIG. 7 shows the top view of the device with the second fastener method
DETAILED DESCRIPTION
[0013] This invention is a training device used to help teach athletes how to properly throw a forehand or flick throw of a flying disc, such as Frisbee. The device teaches players how to keep their wrist straight when throwing forehand throws. The device can have the angle of its platform changed to practice throwing high and low release flicks as well.
[0014] FIG. 1 illustrates the front view of a Frisbee throwing training device 10 with a sleeve 12 . In embodiments, the sleeve can be made from a thermoplastic material, a thermoset material, or other composites. In the embodiment shown, covering the top quarter and bottom quarter of the sleeve 12 is another layer of hook and loop fasteners 14 that may be tightened or loosened to change the fit of the whole device 10 . Extending from the sleeve 12 is a platform 16 . In embodiments, the platform 16 can be made from that is comprised of thermoplastic material, thermoset material, metal, metal alloy, or a metal plastic composite.
[0015] FIG. 2 illustrates a side view of a Frisbee throwing training device 10 . Attached to the sleeve 12 is an adjustable joint 18 . The joint 18 allows for the angle between sleeve 12 and platform 16 to be adjusted manually. In the embodiment shown, joint 18 is a socket, half spherical in shape with a spherical indent hollowing out the component. In embodiments, the joint can be made from thermoplastic material, thermoset material, metal, metal alloy, or a metal plastic composite. Imbedded into 18 is a screw 20 that may be dome, cylindrical, or hexagonal on the outer head.
[0016] FIG. 3 demonstrates the 120 degree angle that can adjusted and fixed formed between the sleeve and the platform 16 . This can be achieved by maneuvering the platform across the axis of rotation provided through the joint 18 formed between the interaction of joint 18 and platform 16 .
[0017] FIG. 4 demonstrates the 90 degree angle that can adjusted and fixed formed between the sleeve and the platform 16 . This can be achieved by maneuvering the platform across the axis of rotation provided through the ball joint formed between the interaction of joint 18 and platform 16 .
[0018] FIG. 5 1 illustrates the front view of a Frisbee throwing training device 10 with a sleeve 12 . Attached to sleeve 12 are another type of fastener systems 114 that can be tightened or loosened to change the fit of the whole device 10 . Extending from the sides of sleeve are loops 115 that the fastening straps 114 are threaded through.
[0019] FIG. 6 illustrates the top view of the Frisbee throwing training device 10 when it is using the fastener system 14 . While the user's wrist is not shown, the sleeve 12 surrounds the user's wrist.
[0020] FIG. 7 illustrates the top view of the Frisbee throwing training device 10 when it is using the fastener system 114 . While the user's wrist is not shown, the sleeve 12 surrounds the user's wrist.
[0021] While the embodiment shown in the drawings contains a ball joint, other suitable joints can be used, including, but not limited to a knuckle joint, a revolute joint, and a cylindrical joint. While the embodiment shown in FIG. 1 contains hook and loop fasteners, other suitable fasteners can be used, including but not limited to elastic fasteners.
[0022] While the embodiment shown in the drawings includes a tubular sleeve, other configurations can be used, including, but not limited to a flat material that can be wrapped around in order to form the tube. The length of the sleeve may also be variable and not limited to lengths mentioned within.
[0023] An optimal angle for the platform to be set at in order to throw a fiat forehand throw is about 170 degree angle to about 190 degree angle formed between the sleeve and the platform. An optimal angle for the platform to be set at in order to throw a low release forehand throw is about 140 degree angle to about 160 degree angle formed between the sleeve and the platform. An optimal angle for the platform to be set at in order to throw a high release is about 210 degree angle formed between the sleeve and the platform. These recommended angles may need to be adjusted depending on each user.
[0024] A number of alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims. | Wrist and/or forearm support and Frisbee training apparatus, comprising a rigid sleeve configured for the application to the wrist and/or forearm that is adjustable and can be modified to the user, a platform configured to limit the rotational movement of the user's wrist, and a connection between the top of the sleeve and the bottom of the portion. | 0 |
RELATED PATENTS
[0001] This patent stems from a continuation application of U.S. patent application Ser. No. 09/186,246, and filing date of Nov. 4, 1998, entitled HIGH DATA RATE SPREAD-SPECTRUM SYSTEM AND METHOD by inventor, DONALD L. SCHILLING. The benefit of the earlier filing date of the parent patent application is claimed for common subject matter pursuant to 35 U.S.C. §120.
BACKGROUND OF THE INVENTION
[0002] This invention relates to communications, and more particularly to a high data rate spread-spectrum system.
DESCRIPTION OF THE RELEVANT ART
[0003] In a fixed bandwidth CDMA system, increasing the data rate reduces the processing gain. To maintain a high data rate, the prior art teaches the transmission of spread-spectrum signals with parallel orthogonal chip-sequence signals. The use of parallel chip-sequence signals, however, results in increased interference in the receiver due to multipath. In addition, when transmitting parallel chip-sequence signals, the transmitted output signal usually is distorted as a result of nonlinearities in the output amplifiers and filters.
[0004] [0004]FIGS. 1 and 2 show a prior art spread-spectrum system, transmitting data at high processing gain. The example is for an encoded data rate of 100 megabits per second (Mb/s), although any data rate could be used. The data are demultiplexed by demultiplexer 45 into four data streams, each with a symbol rate of 25 mega-symbols/second. Four product devices 41 , 42 , 443 , multiply the four data streams by four orthogonal chip-sequence signals g 1 (t), . . . , g 4 (t), from chip-sequence generator 44 , which have a chip rate of 400 mega-chips/second. The four chip-sequence signals could be sent as five-level pulse amplitude modulation (PAM), by multiplying by cos ω 0 t or as three amplitudes in each of cos ω 0 t and sin ω 0 t axes. The outputs from the product devices 41 , 42 , 443 are combined by combiner 46 , and transmitted as a radio wave, at a carrier frequency ω 0 , over a communications channel. Signal source 16 and product device 15 translate the output from combiner 46 to the carrier frequency, using a standard up-converter device. The antenna 17 is coupled to the radio wave to the communications channel.
[0005] The receiver has four matched filters 711 , 712 , 714 for detecting the four parallel signals. At the receiver, antenna 24 , product device 25 and receiver signal source 26 receive and translate the multichannel spread-spectrum signal to a processing frequency. The multiplexer 54 multiplexes the outputs from the matched filters 711 , 712 , 714 . De-interleaver 37 de-interleaves the multiplexed data, and FEC decoder 38 decodes the de-interleaved data as estimated data.
[0006] Multipath causes delayed versions of g 1 (t), g 2 (t), g 3 (t) and g 4 (t) to be present at each matched filter. Consider the first matched filter 711 . The delayed versions are not orthogonal to the first chip-sequence signal g 1 (t) and multipath interference results. The number of interferers is due to the number of parallel codes, number of simultaneous users, etc.
[0007] Further, any multipath signals can be generated by each of the multilevel pulse amplitude modulation signals, which can produce one of M levels for each chip. The number of levels produced is M. This large variation in amplitude results in distortion due to filtering and to nonlinearities in the transmit output amplifier.
SUMMARY OF THE INVENTION
[0008] A general object of the invention is to facilitate the transmission and reception of a high data rate signal using a high processing gain CDMA system without using parallel codes.
[0009] A second object is the efficient acquisition and synchronization of such a signal.
[0010] According to the present invention, as embodied and broadly described herein, an improvement to a spread-spectrum system is provided for sending data over a communications channel. The spread-spectrum system is assumed to handle high data rate communications. The improvement includes, at the transmitter, a memory which typically is coupled to a bit interleaver, and a chip-sequence encoder, which is coupled to the memory and to a transmitter section. At the receiver, the improvement includes a plurality of product devices, a plurality of integrators, a comparator, and a chip-sequence-signal generator and controller.
[0011] At the transmitter, the memory stores N bits of interleaved data, or other data, from an interleaver, or other data source, respectively. The chip-sequence encoder uses the N bits of stored data for selecting one of 2 N orthogonal chip-sequence signals stored in the chip-sequence encoder. The chip-sequence encoder outputs the selected chip-sequence signal. The number of bits, N, is the number of bits in a symbol, used for selecting one of the 2 N chip-sequence signals. While orthogonal signals are preferred, near-orthogonal signals also can be employed, albeit at the cost of a slightly higher error rate.
[0012] At the receiver, at the processing frequency, 2 N correlators are employed, one for each of the 2 N possible signals. The outputs from the 2 N correlators are compared, and the output with the largest value is chosen. 2 N matched filters also could be employed, however, using matched filters is not a preferred approach since 2 N matched filters would require more gates, and therefore more cost.
[0013] For acquisition, the 2 N product devices multiplies the received header of the spread-spectrum signal by a replica of the header signal, which is stored or generated at the receiver, and which typically is taken from the plurality of 2 N chip-sequence signals. Each correlator is delayed, one from the other, by one-half chip in a preferred system. The chip-sequence signal has the first chip-sequence signal, and has a delay of at least one chip with respect to each chip-sequence signal from the plurality of 2 N chip-sequence signals. Each chip-sequence signal has a different delay from other chip-sequence signals from the plurality of 2 N chip-sequence signals. Timing is obtained by using the timing of the correlator with the largest output.
[0014] The plurality of product devices, after acquisition, multiplies the received spread-spectrum signal by the plurality of 2 N chip-sequence signals, with each chip-sequence signal from the plurality of 2 N chip-sequence signals having a different chip-sequence signal from other chip-sequence signals from the plurality of 2 N chip-sequence signals. The plurality of integrators are coupled to the plurality of product devices, respectively. The plurality of integrators integrate a plurality of products from the plurality of product devices during the period of a chip-sequence signal. The comparator, which is coupled to the plurality of integrators, selects a largest value from the plurality of integrators. The chip-sequence decoder decodes the largest value from a respective integrator of the plurality of integrators into N bits of data or interleaved data, depending on the originating source at the transmitter.
[0015] Additional objects and advantages of the invention are set forth in part in the description which follows, and in part are obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention also may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention, and together with the description serve to explain the principles of the invention.
[0017] [0017]FIG. 1 illustrates a prior art approach for transmitting data at a high rate in a CDMA system;
[0018] [0018]FIG. 2 illustrates a prior art approach for receiving data at a high rate in a CDMA system;
[0019] [0019]FIG. 3 is a block diagram of a transmitter for increasing processing gain in a high data rate system for orthogonal BPSK;
[0020] [0020]FIG. 4 is a block diagram of a transmitter for increasing processing gain in a high data rate system for bi-orthogonal BPSK;
[0021] [0021]FIG. 5 is a block diagram of a transmitter for increasing processing gain in a high data rate system for orthogonal QPSK;
[0022] [0022]FIG. 6 is a block diagram of a transmitter for increasing processing gain in a high data rate system for bi-orthogonal QPSK;
[0023] [0023]FIG. 7 is a block diagram of a receiver for increasing processing gain in a high data rate system for BPSK; and
[0024] [0024]FIG. 8 is a block diagram of a receiver for increasing processing gain in a high data rate system for QPSK.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Reference now is made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals indicate like elements throughout the several views.
[0026] The invention disclosed in this patent is a novel approach to increasing data rate over a spread-spectrum system. The claimed invention may be manufactured, in whole or in part, as a digital signal processor (DSP), as an application specific integrated circuit (ASIC), from a general purpose processor, from discrete and/or analog electronic components, or as a combination of one or more of the DSP, ASIC, general purpose processor and discrete and/or analog components.
[0027] The present invention broadly includes FEC means, interleaver means, memory means, chip-encoder means, transmitter means, receiver means, spread-spectrum means, comparator means, chip-decoder means, deinterleaver means, and FEC-decoder means. The interleaver means is coupled between the FEC-encoder means and the memory means. The chip-encoder means is coupled between the memory means and the transmitter means. The transmitter means is coupled to the communications channel.
[0028] The receiver means is coupled to the communications channel. The spread-spectrum means is coupled between the receiver means and the comparator means. The chip-decoder means is coupled between the comparator means and the deinterleaver means.
[0029] The FEC-decoder means is coupled to the deinterleaver means. The FEC-encoder means encodes with an FEC code, the data as FEC data. FEC data, as used herein, are the encoded data from any data source which are at the output of the FEC-encoder means.
[0030] The interleaver means interleaves the FEC data as interleaved data. The memory means stores N bits of interleaved data as stored data. As used herein, stored data are the data stored in the memory means. N is the number of bits in a particular symbol.
[0031] The chip-encoder means selects a chip-sequence signal, based on the N bits of stored data, from one of 2 N chip-sequence signals stored in the chip-encoder means. The selected chip-sequence signal is an output chip-sequence signal. In a preferred system, the 2 N chip-sequence signals are orthogonal and each chip-sequence signal has 2 N chips. Alternatively, 2 N /2 orthogonal chip-sequence signals can be selected and each chip-sequence signal can be sent as a positive or negative signal, creating bi-orthogonal signaling.
[0032] The transmitter means translates the output chip-sequence signal to a carrier frequency and transmits the output chip-sequence signal at the carrier frequency as a radio wave over a communications channel, as a binary phase-shift-keyed (BPSK) or as a quaternary phase-shift-keyed (QPSK) spread-spectrum signal.
[0033] The receiver means translates the spread-spectrum signal received to a processing frequency. Because of the ease of digital processing, a preferred procedure is to translate, or down convert, the received spread-spectrum signal to baseband.
[0034] The spread-spectrum means, for acquisition, multiplies the received spread-spectrum signal by a plurality of “header” chip-sequence signals. Each header chip-sequence signal has an identical chip sequence. Each header chip-sequence signal has a different delay from the other header chip-sequence signals. The preferred delay is one-half chip duration, although one chip duration is also workable. This accomplishes acquisition, by multiplying the received spread-spectrum signal by an identical chip-sequence signal, with different delays. The output of each multiplier is added forming a correlation, and the correlator with the largest output is selected. This approach permits the same 2 N correlators used for demodulation to be used for acquisition by changing the multiplying signals. A matched filter, however, could be used for acquisition, but using a matched filter would increase hardware. Using a matched filter as a separate circuit for acquisition, which would be in addition to the embodiment disclosed herein, is well know in the art.
[0035] After acquisition, the spread-spectrum means changes from multiplying by an identical “header” chip-sequence signal to multiplying by the 2 N different chip-sequence signals of the plurality of 2 N chip-sequence signals. Accordingly, after acquisition, the received spread-spectrum signal is multiplied by each of the chip-sequence signals in the plurality of chip-sequence signals, with each chip-sequence signal in the plurality of chip-sequence signals having a different chip sequence from other chip-sequence signals from the plurality of chip-sequence signals. The outputs of each multiplier is added so that each multiplier-adder is a correlator.
[0036] The comparator means selects the largest value at the output of the spread-spectrum means at each symbol time T s .
[0037] The decoder means 36 decodes the largest value from the comparator means as an N-bit sequence or series of N-bits.
[0038] The deinterleaver means deinterleaves the series of bits from chip-decoder means to deinterleaved data, and the FEC-decoder means decodes the deinterleaved data as estimated data.
[0039] The data, d(t), are FEC encoded and interleaved, and successive N bits are stored. Each N bit sequence is considered a symbol. For each N bits, one of 2 N orthogonal sequences is selected. Each sequence has 2 N chips/symbol. Each sequence is then amplitude modulation (AM) modulated. Thus the following signal is sent:
k i ( t )cos ω 0 ti =1, 2, . . . , 2 N
[0040] or
k i ( t ) cos ω o t + h j ( t ) sin ω o t i = 1 , 2 , … , 2 N 2 j = 1 , 2 , … , 2 N 2
[0041] Alternatively, bi-orthogonal signaling may be used by sending
p i ( t )cos ω 0 t
[0042] [0042] i = 1 , 2 , … , 2 N 2
[0043] or
± g i ( t )cos ω 0 t±h j ( t )cos ω 0 t
[0044] [0044] i = 1 , 2 , … , 2 N 4 j = 1 , 2 , … , 2 N 4
[0045] where each waveform is orthogonal or bi-orthogonal to the others. In the receiver, 2 N correlators are used. If bi-orthogonal coding were used, then 2 N−1 correlators are required.
[0046] The relevant formulas are:
[0047] Processing Gain (PG)=2 N chips/symbol
f
s
=f
b
/N
[0048] [0048] f c = 2 N f s = 2 N N f b
[0049] Where f b is frequency (bandwidth) of bits, f c is frequency (bandwidth) of chips, and f s is frequency (bandwidth) of symbols.
[0050] The number of correlators, or matched filters, needed are:
[0051] 2 N /N for orthogonal coding
[0052] 2 N /2N for bi-orthogonal coding
[0053] For example:
f b =100 Mb/s
[0054] and PG=16
[0055] Then
[0056] 16=2 N and N=4
[0057] f s =f b /N=25 MHz
[0058] and
[0059] f c =400 MHz
[0060] N=4 for orthogonal coding
[0061] N=2 for bi-orthogonal coding
[0062] In the exemplary arrangement shown in FIGS. 3 - 6 , the improvement to the transmitter includes, by way of example, a forward-error-correction (FEC) encoder 11 , interleaver 12 , and memory 13 . In FIGS. 3 and 4, a chip-sequence encoder 14 is employed for selecting one of 2 N chip-sequence signals. The transmitter section, in FIGS. 3 and 4, includes a product device 15 , a signal source 16 , and an antenna 17 . Additional amplifiers and filters may be employed in the transmitter section, as is well known in the art. The interleaver 12 is coupled between the FEC encoder 11 and the memory 13 . The chip-sequence encoder 14 is coupled between the memory 13 and the product device 15 . The signal source 16 is coupled to the product device 15 , and the antenna 17 is coupled to the product device 15 .
[0063] The FEC encoder 11 , of FIGS. 3 - 6 , encodes the data with an FEC code. A convolutional encoder, concatenated coder comprising a convolutional and a Reed Solomon (RS) encoder, or other error-correcting codes can be used. The output of the FEC encoder 11 is denoted herein as FEC data.
[0064] The interleaver 12 interleaves the FEC data, using a bit interleaver algorithm as is well known in the art. The output of the interleaver 12 is denoted herein as interleaved data.
[0065] The memory 13 stores N bits of data. The data may come from the interleaver 12 , and from other sources, such as signaling and other overhead data into the memory 13 . The data stored in the memory 13 is denoted herein as stored data. The number N represents the number of bits per symbol. The symbols are used or represented for a particular chip-sequence at the chip-sequence encoder 14 .
[0066] Referring to FIGS. 3 and 4, the chip-sequence encoder 14 uses N bits of stored data for selecting a particular chip-sequence signal from a plurality of chip-sequence signals. The plurality of chip-sequence signals, in a preferred embodiment, includes 2 N orthogonal chip-sequence signals. The 2 N chip-sequence signals are stored in the chip-sequence encoder 14 . In response to the N bits of data stored each symbol time T s , one of the 2 N signals is outputted from the chip-sequence encoder 14 . The output of the chip-sequence encoder 14 is denoted herein as an output chip-sequence signal. In FIG. 4, the output of the chip-sequence encoder 14 is multiplied by gate 115 with a plus or minus one, to generate a bi-orthogonal BPSK signal.
[0067] Referring to FIGS. 5 and 6, the chip-sequence encoders 214 , 314 uses 2 N /2 bits of stored data for selecting a particular chip-sequence signal from a plurality of chip-sequence signals. The plurality of chip-sequence signals, in a preferred embodiment, includes 2 N /2 bi-orthogonal chip-sequence signals. The 2 N /2 chip-sequence signals are stored in chip-sequence encoders 214 , 314 . In response to the N bits of data stored each symbol time T s , one of the 2 N /2 signals is outputted from the chip-sequence encoders 214 , 314 . The output of the chip-sequence encoder 214 is denoted herein as a quadrature-phase output chip-sequence signal, and the output from the chip-sequence encoder 314 is denoted herein as an in-phase chip-sequence signal. The signal source 16 generates an in-phase carrier signal, and phase shifter 416 generates the quadrature-phase carrier signal, as is well known in the art.
[0068] In FIG. 6, the outputs of the chip-sequence encoders 214 , 314 are multiplied by multiplier devices 216 , 316 , respectively, by the quadrature-phase carrier signal and the in-phase carrier signal, and by gates 217 , 317 , respectively, with a plus or minus one, to generate a bi-orthogonal QPSK signal.
[0069] The transmitter section translates the output chip-sequence signal to a carrier frequency, and transmits, as a radio wave, the output chip-sequence signal at the carrier frequency over a communications channel. The transmitted signal is a spread-spectrum signal.
[0070] At the transmitter section in FIGS. 3 and 4, the signal source 16 generates the signal for translating the output chip-sequence signal to the particular carrier frequency, and the product device 15 multiplies the output chip-sequence signal to the carrier frequency. The resulting product is the spread-spectrum signal which is radiated by the antenna 17 . For FIGS. 3 and 4 the product device 15 and signal source 16 are shown for an in-phase carrier.
[0071] At the transmitter section in FIGS. 5 and 6, the signal source 16 generates the signal for translating the output chip-sequence signal to the particular carrier frequency, and the product devices 216 , 316 multiplies the output chip-sequence signal to the carrier frequency. The phase-shift device 416 generates the quadrature component from the signal source 16 . The resulting product is the spread-spectrum signal which is radiated by the antenna 17 . Note that in FIGS. 5 and 6, a set of quadrature carriers, cos ω 0 t and sin ω 0 t, are generated in place of a simple in-phase carrier, of FIGS. 3 and 4.
[0072] [0072]FIG. 7 shows how the basic receiver circuit, shown in FIG. 2, is modified by the addition of a sequence detector that detects a symbol header. This decoder could be a simple matched filter which operates on the symbols.
[0073] At the receiver, the receiver section translates the spread-spectrum signal to a processing frequency. The receiver section has an antenna 24 which is coupled to the communications channel, and a signal source 26 . The signal source 26 generates a signal which translates the received spread-spectrum signal by the mixer or product device 25 , to the processing frequency. In practice, as shown in FIG. 8, two quadrature terms are obtained by multiplying by cos ω 0 t and sin ω 0 t and using standard receiver circuits. FIG. 8 illustrates an in-phase device 25 and a quadrature-phase device 225 , coupled to a signal source 26 for cos ω 0 t and a signal source 226 for sin ω 0 t. Alternatively, a single signal source and a phase shifter could be use to generate the cos ω 0 t and sin ω 0 t signals.
[0074] In FIG. 7, the plurality of product devices 21 , 22 , 23 are coupled to the product device 25 . The plurality of product devices 21 , 22 , 23 operates in cooperation with the chip-sequence-signal generator and controller 27 . For acquisition, a “header” chip-sequence signal is generated by the chip-sequence-signal generator and controller 27 . The header chip-sequence signal is generated as a plurality of header chip-sequence signals, with each chip-sequence signal in the plurality of header chip-sequence signals having a delay of one-half chip or one chip delay with respect to each other chip-sequence signal in the plurality of header chip-sequence signals. Thus, each of the header chip-sequence signals in the plurality of header chip-sequence signals has an identical chip sequence as the first chip-sequence signal, but with a different delay. The plurality of product devices 21 , 22 , 23 multiplies the received spread-spectrum signal by the plurality of header chip-sequence signals, each with a respective, different delay. At the output of the plurality of product devices 21 , 22 , 23 , the plurality of integrators 31 , 32 , 33 integrates, respectively, a plurality of products from the plurality of product devices 21 , 22 , 23 . The products are integrated for a period of a header-chip-sequence signal.
[0075] The quadrature detection embodiment of FIG. 8 operates functionally equivalent to the in-phase embodiment described for FIG. 7, with the addition of quadrature-phase products devices 221 , 222 , 223 and quadrature-phase integrators 231 , 232 , 233 . A set of a product device 21 and an integrator 31 , comprise a correlator, as is well known in the art.
[0076] The comparator 35 selects a largest value from the plurality of integrators 31 , 32 , 33 , and for the quadrature-phase embodiment, of FIG. 8, also from the plurality of integrators 31 , 32 , 33 , 231 , 232 , 233 . When the largest value is selected by the comparator 35 , a control signal is sent to the chip-sequence signal-generator and controller 27 , as to which of the particular paths from the plurality of product devices 21 , 22 , 23 and the respective plurality of integrators 31 , 32 , 33 has the largest value. The chip-sequence-signal generator and controller 27 locks onto the timing of the selected signal path.
[0077] Alternatively, a separate matched filter receiver could be used to detect the header and achieve synchronization.
[0078] When the chip-sequence-signal generator and controller 27 are locked into the timing, the chip-sequence-signal generator and controller 27 generates a plurality of chip-sequence signals, with each chip-sequence signal different from the other chip-sequence signals in the plurality of chip-sequence signals and each being one of the 2 N , or 2 N /2, possible transmitted signals. Thus, each chip-sequence signal from the chip-sequence-signal generator and controller 27 is different from the other chip-sequence signals in the plurality of chip-sequence signals, by having a different chip sequence from other chip-sequence signals. The plurality of chip-sequence signals are fed to the plurality of product devices 21 , 22 , 23 , in time synchronization with the received spread-spectrum signal, since acquisition has been achieved.
[0079] Acquisition is achieved by transmitting a prescribed number of chips to form the header. For example, if the desired signal-to-noise ratio (SNR) at the correlator output for a single sequence were 20 dB, and the SNR of a chip were −10 dB, then a sequence of 1000 chips is adequate. In this case, assuming a chip rate of 4 Megachips/second, the acquisition time T A =(1000/4) microseconds=250 microseconds.
[0080] After acquisition, the plurality of product devices 21 , 22 , 23 , the chip-sequence-signal generator and controller 27 , and plurality of integrators 31 , 32 , 33 serve to demodulate which chip-sequence signal is embedded in the received spread-spectrum signal. The strongest signal path from the plurality of integrators 31 , 32 , 33 is selected by comparator 35 as the detected signal. Upon detecting a particular chip-sequence signal from a particular path, the selected chip-sequence signal is decoded to N bits by chip decoder 36 . The de-interleaver 37 deinterleaves the interleaved N bits and the FEC decoder decodes the deinterleaved data. An estimate of data is output from the FEC decoder 38 .
[0081] To ensure timing accuracy, the system could sample two or more times per chip. For data rates between 64 kb/s and 2 Mb/s, technology permits sampling at four times the chip rate. However, at data rates of 100 Mb/s and a chip rate of 400 Mchips/s, one or two samples per chip appears to be the technological limit today.
[0082] [0082]FIG. 8 shows that quadrature detection is actually employed.
[0083] The present invention also includes a spread-spectrum method improvement for sending data over a communications channel, comprising the steps of storing, at a transmitter, N bits of interleaved data as stored data, with N a number of bits in a symbol, and selecting, at the transmitter in response to he N bits of stored data, a chip-sequence signal from a plurality of chip-sequence signals, as an output chip-sequence signal. The method then comprises the steps of transmitting the output chip-sequence signal as a radio wave, at a carrier frequency, over the communications channel, as a spread-spectrum signal and, translating, at a receiver, the spread-spectrum signal to a processing frequency as a received spread-spectrum signal. For acquisition, the received spread-spectrum signal is multiplied, at the processing frequency, by a header chip-sequence signal from the plurality of chip-sequence signals, with each chip-sequence signal having an identical chip sequence as the header chip-sequence signal, but with each chip-sequence signal having a delay of one-half or one chip, with each chip-sequence signal from the plurality of chip-sequence signals having a different delay from other chip-sequence signals. After acquisition, the received spread-spectrum signal is multiplied by the plurality of chip-sequence signals, with each chip-sequence signal from the plurality of 2 N chip-sequence signals having a different chip sequence from other chip-sequence signals in the plurality of chip-sequence signals, respectively. A plurality of products from the plurality of product devices are integrated during a period of a chip-sequence signal, and a largest value is selected from the plurality of integrators. The largest value from a respective integrator of the plurality of integrators is decoded into N bits of interleaved data.
[0084] The invention preferably uses orthogonal or bi-orthogonal signaling to increase the processing gain. The result is a binary AM signal (BPSK) or a QPSK signal and, therefore, the waveform is not degraded by amplifier nonlinearities. Further, since only one waveform is sent and RAKE is employed in the receiver, multipath can be used to enhance performance.
[0085] It will be apparent to those skilled in the art that various modifications can be made to the technique to acquire synchronization in high data rate CDMA systems of the instant invention without departing from the scope or spirit of the invention, and it is intended that the present invention cover modifications and variations of the technique to acquire synchronization in high data rate CDMA systems provided they come within the scope of the appended claims and their equivalents. | A high data rate, high processing gain, direct sequence spread spectrum system that transmits a BPSK or QPSK signal. The system FEC encodes and interleaves data which are collected and stored and forwarded N bits at a time by transmitting one of 2 N pseudo random waveforms every time N bits are collected. The 2 N pseudo random waveforms can be sent as an orthogonal, bi-orthogonal, or nearly orthogonal waveform. During acquisition, a plurality of product devices multiply a received spread-spectrum signal by a header chip-sequence signal. In each case, the header chip-sequence signal has a different delay, with each delay being at most one chip. Acquisition can also be achieved using a matched filter. After acquisition, the plurality of product device multiply the received spread-spectrum signal by 2 N chip-sequence signals to generate a plurality of products, with each chip-sequence signal of the plurality of chip-sequences signals being different from other chip-sequence signals of the plurality of chip-sequence signals; a plurality of integrators integrate the plurality of products thereby forming 2 N correlators, and a comparator selects a largest value from the plurality of integrators. The largest value is decoded into N bits of data. This process is repeated for each N bit word received. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a bimetal and more particularly to a bimetal which is rapidly deflected at an optionally specified high temperature and indicates a satisfactory reversible behavior depending on temperature change.
The deflection of the prior art bimetal generally proceeds at a substantially fixed rate in proportion to temperature change. Where, therefore, it was desired to use the known bimetal in such application as required the bimetal to make a rapid deflection over a prescribed temperature range, for example, the application where a bimetal was directly used in a contact drive mechanism, it was necessary to provide an additional quick responsive drive mechanism. The quick responsive drive mechanism includes, for example, a repulsion board, magnet or spring. A combination of a bimetal and any of these quick responsive drive mechanisms enabled the original slow deflection of the bimetal itself to be carried out quickly. However, a bimetal device which was provided with the above-mentioned quick responsive drive mechanism had the drawbacks that the bimetal device as a whole became bulky and had to be manufactured with a complicate design.
The known bimetal indicating a rapid deflection over a certain temperature range includes martensite transformation such as an Ni-Ti alloy utilizing a shape memory effect. This shape memory type alloy has to be deformed under a specified temperature condition before being used as a bimetal. And, said shape memory type alloy does not indicate the same rate of deflection when used frequently, failing to be effectively used in practice. Moreover, the above-mentioned type of bimetal had the drawbacks that it indicated a rapid deflection at a relatively low temperature, and had insufficient workability and bandability, presenting difficulties in manufacture.
A bimetal rapidly deflectable at a specified temperature is generally used for temperature control of household electric appliances and as a safety device for various industrial apparatuses. Therefore, the above-mentioned bimetal is desired to have as high an anticorrosive property as possible.
SUMMARY OF THE INVENTION
It is accordingly an object of this invention to provide a novel bimetal which makes a rapid deflection over a specified temperature range without the aid of the aforesaid quick responsive drive mechanism, that is, a bimetal whose high expansion layer is prepared from the known iron-manganese alloy containing manganese causing the resultant bimetal to have a high thermal expansion coefficient, and indicates prominent workability and bondability and a satisfactory reversible behavior relative to temperature change.
Another object of the invention is to provide a novel bimetal of the above-mentioned type which is further rendered anticorrosive.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a vertical sectional view of bimetal according to this invention; and
FIG. 2 shows the deflection of the free end of the bimetal of this invention relative to temperature change and that of the prior art bimetal.
DETAILED DESCRIPTION OF THE INVENTION
A bimetal according to this invention comprises a first alloy component which rapidly indicates a deflection greater than 50×10 -6 /°C. at an optionally specified high temperature, and a second alloy component which is bonded to the first alloy component and whose thermal expansion coefficient remains substantially fixed relative to temperature change. The second alloy component has substantially the same thermal expansion coefficient as that which is indicated by the first alloy component at a temperature lower than that at which the thermal expansion coefficient of said first alloy component rapidly increases.
The first alloy component is formed of 15 to 30% by weight of manganese and substantially iron as the remainder. Or the first alloy component is prepared from 15 to 30% by weight of manganese, and a member selected from the group consisting of 2 to 15% by weight of chromium, 2 to 15% by weight of cobalt and 2 to 20% by weight of a mixture of chromiun and cobalt, and substantially iron as the remainder.
The first alloy used as the high expansion component of the present bimetal has its composition specifically restrictively defined for the following reasons.
Manganese is an important element to increase the thermal expansion coefficient of a bimetal and also cause the thermal expansion coefficient to be rapidly varied relative to temperature change. The amount of manganese needed to cause the thermal expansion coefficient to be rapidly varied at an optionally specified temperature ranges from 15 to 30% by weight, and preferably 15 to 25% by weight. The thermal expansion coefficient of a bimetal indicates a value of approximately 50×10 -6 to 400×10 -6 /°C. near that point included in the above-mentioned range of the manganese content at which a rapid change occurs in the thermal expansion coefficient.
Chromium is an important element in a bimetal having a high anticorrosive property. The amount of chromium required to improve the anticorrosive property is selected to be over 2% by weight. The amount of chromium needed to let the thermal expansion coefficient of a bimetal fall within the above-mentioned range has been found to be less than 15% by weight. Therefore, the prescribed content of chromium is set between 2% and 15% by weight.
Cobalt has the same function as chromium, and its content is also preferred to range from 2% to 15% by weight for the reason given above.
With this invention, it is possible to use both chromium and cobalt for improving the anticorrosive property of a bimetal. In this case, it is preferable advised to mix both elements in a total amount larger than 2% by weight in order to increase the anticorrosive property of a bimetal. Further, the total content of a mixture of chromium and cobalt should be less than 20% by weight or preferably 15% by weight.
Impurities are unavoidably carried into the raw materials of the present bimetal such as carbon, oxygen, nitrogen, sulphur, phosphorus, and aluminium or silicon purposely added as a deoxidant at the time of disolution of the raw materials will not obstruct one effect of the bimetal according to this invention, provided the total amount of all these materials is less than 1% by weight. Nickel, known as an element adapted to increase the anticorrosive property of a bimetal will not reduce the effect of the present bimetal, provided the nickel content is smaller than 3% by weight.
The second alloy constituting the low thermal expansion component of the bimetal of this invention is formed of Invar, for example, an iron-nickel system (the nickel proportion ranging between 36% and 50% by weight). The second alloy is preferred to be the type whose thermal coefficient remains substantially fixed near that temperature at which the thermal expansion coefficient of the first alloy constituting the high thermal expansion component of the present bimetal commences to increase rapidly, and further is smaller than the increased thermal expansion coefficient of the first alloy.
The second alloy of low thermal expansion should preferably be prepared from an alloy having substantially the same thermal expansion coefficient as that which is indicated by the first alloy of high thermal expansion at a lower temperature than that at which the thermal expansion coefficient of said first alloy begins to increase rapidly, for example, austenitic stainless steel such as SUS304, SUS310. Application of the second alloy of the above-mentioned type prominently increases the effect of this invention.
This invention will be more fully understood by reference to the examples which follow.
EXAMPLE 1
First, experiments were made on the deflection of a bimetal relative to temperature change to examine its behavior characteristics. For these experiments, alloys having the compositions shown in Table 1 below were selected. Samples were prepared by melting the alloys in a high frequency induction furnace, followed by annealing for thorough elimination of strains. Measurement was made of the thermal expansion coefficients (abbreviated as "TEC") of the alloy samples and the temperatures at which said thermal expansion coefficients indicated a rapid change, the results being set forth in Table 1 below. Measurement was further made of the thermal expansion coefficients indicated by the alloy samples before and after the temperature of rapid deformation was reached, and also of the thermal expansion coefficients indicated by the alloy samples over the temperature range from room temperature to 200° C.
Table 1__________________________________________________________________________ TEC over a range from Temperature of TEC before TEC after room temper-Sample Chemical Composition rapid change said rapid said rapid ature toNo. Fe Mn Ni Cu Cr in TEC (°C.) change change 200° C.__________________________________________________________________________ No rapid de-1 bal. 6.3 -- -- -- formation -- -- 12.8 × 10.sup.-6 /°C.2 " 10.0 -- -- -- No rapid de- -- -- 15.5 × 10.sup.-6 /°C. formation3 " 15.8 -- -- -- 228 17.5 × 10.sup.-6 /°C. 52.0 × 10.sup.-6 /°C. --4 " 18.0 -- -- -- 217 18.7 201 --5 " 20.3 -- -- -- 209 21.5 233 --6 " 25.0 -- -- -- 161 20.5 175 --7 " 28.9 -- -- -- 150 18.2 94.2 --8 " 30.0 -- -- -- 121 17.6 53.4 -- No rapid de-9 " 40.8 -- -- -- formation -- -- 11.5 × 10.sup.-6 /°C.10 -- Bal. 11.0 18.3 -- No rapid de- -- -- 28.6 × 10.sup.-6 /°C. formation11 Bal. 1.05 9.11 -- 17.9 No rapid de- -- -- 17.8 × 10.sup.-6 /°C. formation12 " 1.22 20.3 -- 24.7 No rapid de- -- -- 16.9 × 10.sup.-6 /°C. formation13 " 0.4 36.7 -- -- No rapid de- -- -- 2.57 × 10.sup.-6 /°C. formation14 " 0.55 42.0 -- -- No rapid de- -- -- 5.40 × 10.sup.-6 /°C. formation__________________________________________________________________________
As apparent from Table 1 above, the samples Nos. 3 to 8 among the samples Nos. 1 to 10 of high thermal expansion alloys used in the above-mentioned experiment represent those whose thermal expansion coefficients rapidly changed at the respective definite temperature levels. The samples Nos. 11 to 14 denote alloys of low thermal expansion. The second Fe-Mn alloy of low thermal expansion used with this invention has substantially the same thermal expansion coefficient as the alloy samples Nos. 11, 12 of Table 1. The alloy samples Nos. 11, 12 were austenitic stainless steel SUS304 and SUS310.
The high thermal expansion alloy samples 2 and low thermal expansion alloy samples 3 shown in Table 1 were combined as shown in Table 2 below to produce bimetal samples 1 (FIG. 1).
Table 2______________________________________ Modulus ofSam- Sample Nos. of Table 1 longitudinalple High thermal ex- Low thermal elasticityNo. pansion alloy expansion alloy (kg/mm.sup.2)______________________________________15 10 13 12500 Control16 1 13 14700 "17 3 13 15700 Example18 5 13 15400 "19 7 13 15100 "20 9 13 13400 Control21 1 11 15800 "22 3 11 17500 Example23 5 11 17600 "24 7 11 17600 "25 9 11 14100 Control26 1 12 16200 "27 3 12 17800 Example28 5 12 18300 "29 7 12 18100 "30 9 12 14700 Control______________________________________
The bimetal samples were prepared in the following manner. The alloy samples of high and low thermal expansion were thermal forged into thick plates. The upper surface of each forged plate was ground and the lower surface thereof was finished by brushing. Both alloy plates were bonded together by rolling at a temperature of 900° C. to 950° C. with both plates made to have a thickness ratio of 1:1. After thus rolled, both plates were further subjected to cold rolling. Annealing was repeated at 1050° C., each time an assembly of laminated plates had its thickness reduced by 35% by rolling in order to eliminate accumulated work strains. A bimetal chip measuring 1 mm×10 mm×100 mm was cut out of the sample thus prepared. Repetion of annealing for thorough elimination of work strains is indispensable to suppress the occurrence of such harmful phase (α' phase) as obstructs a rapid change in the thermal expansion coefficient of a bimetal at a specified temperature (shown in Table 1). Said annealing may be undertaken before or after both alloy layers are bonded together.
Measurement was made of the modulus of longitudinal elasticity of the samples Nos. 15 to 30, the results being also set forth in Table 2. As seen from Table 2 above, the bimetal samples embodying this invention (Nos. 17 to 19, 22 to 24, 27 to 29) had a far more improved modulus of longitudinal elasticity than the controls.
The bimetal samples of Table 2 (Nos. 15 to 30) were further tested on their deflecting property relative to temperature change to determine their behavior characteristics. Determination of the deflecting property was effected by measuring the displacement of the overhung free end portion of each sample 100 mm long, the results being presented in FIG. 1. The arrows shown therein indicate the direction in which the deflection of the respective samples resulting from heating and cooling proceeded. The curve (a) of FIG. 1 denotes the deflecting property of the typical prior art bimetal (sample No. 15) and the curve (b) represents the deflecting property of the bimetal (sample No. 17) of this invention whose high expansion component was formed of a Fe-Mn alloy and chose low expansion component was prepared from a Fe-Ni alloy. The curves (c) to (e) indicate the deflecting property of the bimetals of this invention (samples Nos. 27 to 29) whose high expansion component was formed of a Fe-Mn alloy and whose low expansion component was prepared from austenitic stainless steel SUS310.
As seen from FIG. 1, the deflection of sample No. 15, that is, the typical prior art bimetal (curve (a)) proceeded almost linearly relative to temperature change. In contrast, the bimetals of this invention (curves (b) to (e)) were found to behave very sensitively at a temperature of rapid change in the thermal expansion coefficient and indicate hysteresis by heating and cooling. Further, FIG. 1 shows that a temperature of rapid deflection can be easily set at any desired level by controlling the content of manganese, and that the temperature admitting of rapid deflection substantially falls within a high level range from 100° C. to 250° C. The curves (c) to (e) indicate that the thermal expansion coefficient of the bimetal of this invention whose low expansion alloy component was formed of austenitic stainless steel SUS310 did not rapidly change before the temperature of rapid deflection was reached, because both high and low expansion alloy components and substantially the same thermal coefficient, but that when the temperature of rapid deflection was reached, then said bimetal very sensitively behaved, namely, showed a rapid deflection.
As mentioned above, the bimetal of this invention which is rapidly deflected at a specified temperature is not rapidly fused to a contact drive mechanism when directly used therewith, thereby effecting a satisfactory result. The bimetal of this invention indicates a rapid deflection at a higher temperature than the prior art bimetal utilizing the shape memory effect such as a Ni-Ti alloy. Moreover, the present bimetal shows a rapid deflection over a wider temperature range more broadened than has been possible in the past by properly controlling the content of manganese, chromium or cobalt.
EXAMPLE 2
A bimetal was prepared by the same manufacturing process as used in producing the aforesaid Fe-Mn alloy with chromium and/or cobalt added to a high expansion alloy component in order to render the resultant bimetal anticorrosive. Experiments were made with this bimetal to determine not only the deflecting characteristic as in the preceeding case but also the anticorrosive property. 1 to 20% by weight of chromium and similary 1 to 20% by weight of cobalt were added to the above-mentioned Fe-Mn alloy to such extent that the total amount of a mixture of chromium and cobalt indicated 2 to 20% by weight. The whole mass was melted in a high frequency induction furnace to prepare samples. These samples were also tested for the deflecting property. These high expansion alloy samples were bonded with low expansion alloy samples to provide bimetal samples which were expected to indicate an anticorrosive property. Test showed that the bimetal samples thus prepared had exactly the same deflecting property as the Fe-Mn bimetal.
Experiments on an anticorrosive property were undertaken with the samples having a chemical composition shown in Table 3 below.
Table 3______________________________________ TEC TEC after Temper- before said ature said rapidSam- of rapid rapid changeple Chemical Composition change in change (×10.sup.-6 /-No. Fe Mn Cr Co TEC (°C.) (10.sup.-6 /°C.) °C.)______________________________________101 Bal. 20 1 -- 175 21.4 230102 " 20 2 -- 170 21.5 239103 " 20 5 -- 160 20.9 374104 " 20 10 -- 140 19.8 357105 " 20 15 -- 120 20.2 223106 " 20 20 -- -- -- 16.6*107 Bal. 20 -- 1 176 19.5 268108 " 20 -- 3 164 21.1 283109 " 20 -- 5 169 18.6 267110 " 20 -- 10 158 20.7 251111 " 20 -- 15 154 20.3 173112 Bal. 20 -- 20 -- -- 18.3*113 Bal. 20 1 1 168 21.0 211114 " 20 2 1 160 20.3 205115 " 20 2 5 161 19.2 272116 " 20 5 1 157 18.7 272117 " 20 5 5 151 19.8 232118 " 20 10 3 171 20.1 128119 " 20 10 5 152 19.9 102120 " 20 3 15 143 18.2 68.0121 " 20 5 20 -- -- 17.2*______________________________________
In the grater part of the experiments, the content of manganese was restricted to 20% by weight as shown in Table 3. The low expansion alloy components were prepared from the material of the aforesaid samples Nos. 11, 14. Bimetal samples were provided by combinations of high and low thermal expansion alloy components shown in Table 4
Table 4______________________________________Sample Nos. Weight losSample High expan- Low expan- due to corrosionNo. sion alloy sion alloy (mg/cm.sup.2)______________________________________122 103 11 0.572 Example123 103 14 0.580 "124 101 11 0.872 Control125 101 14 0.902 "126 110 11 0.441 Example127 110 14 0.408 "128 107 11 0.911 Control129 107 14 0.964 "130 118 11 0.245 Example131 118 14 0.251 "132 113 11 0.621 Control133 113 14 0.630 "134 5 11 1.046 "______________________________________
The corrosion test was carried out by dipping the bimetal samples for 100 hours in 5% salt water at room temperature and measuring the subsequent weight loss of said samples, the results being set forth in Table 4 above. As apparent from Table 4, the bimetals of this invention were subject to less weight loss by corrosion, namely, had a higher anticorrosive property than those of the control.
The bimetals of this invention prepared by the method of Example 2 were found not only to indicate a rapid deflection at a specified temperature but also display a prominent anti-corrosive property.
The bimetals of the invention are prepared, as described in the foregoing examples, from inexpensive material with a satisfactory reversible property, and are adapted for use with great economic advantage as a safety device such as a circuit breaker for household electric appliances and a thermal protector for various industrial apparatuses.
Apart from the above-mentioned application of a bimetal utilizing its original function, the bimetal of this invention is easily adapted to be used as an interleaf layer between two laminated nickel or copper plates or as a cover plate for either nickel or copper plate for improvements on the properties of electric appliances, for example, reduction of electric resistance. | A bimetal is disclosed having a high, rapid deflection over a specified temperature range, including a high expansion metal alloy component having a high thermal expansion coefficient that changes rapidly at 50×10 -6 /° C. or greater at a temperature of between about 100° C. and 250° C. and containing from 15-30% by weight of manganese, the balance of iron. The second component has a substantially constant thermal expansion coefficient regardless of the temperature change, and is preferably a stainless steel. These bimetals are used in circuit breakers, thermal protectors and the like. | 8 |
RELATED APPLICATION
This patent application is a U.S. National Stage Filing under 35 U.S.C. 371 from International Patent Application Serial No. PCT/US2008/002811 filed Feb. 29, 2008, and published on Sep. 12, 2008, as WO 2008/109045 A2 and republished as WO 2008/109045 A3, which claims the priority benefit of U.S. Provisional Patent Application Ser. No. 60/904,673 filed Mar. 2, 2007 and entitled “PMMA CEMENT WITH ADAPTED MECHANICAL PROPERTIES” and to U.S. Provisional Patent Application Ser. No. 60/967,052 filed Aug. 31, 2007 and entitled “PMMA CEMENT WITH ADAPTED MECHANICAL PROPERTIES”, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND
Vertebral compression fractures in osteoporotic patients are typically treated by a surgical procedure known as vertebroplasty. In this procedure the fractured vertebral body is augmented with a bone cement. The bone cement polymerizes and hardens upon injection into the vertebral body and stabilizes the fracture. Pain relief for the patient is usually immediate and vertebroplasty procedures are characterized by a high rate of success.
Typically, bone cement is prepared directly prior to injection by mixing bone-cement powder (e.g., poly-methyl-methacrylate (PMMA)), a liquid monomer (e.g., methyl-methacrylate monomer (MMA)), an x-ray contrast agent (e.g., barium sulfate), and an activator of the polymerization reaction (e.g., N, N-dimethyl-p-toluidine) to form a fluid mixture. Other additives including but not limited to stabilizers, drugs, fillers, dyes and fibers may also be included in the bone cement. Since the components react upon mixing, immediately leading to the polymerization, the components of bone cement must be kept separate from each other until the user is ready to form the desired bone cement. Once mixed, the user must work very quickly because the bone cement sets and hardens rapidly.
Other examples of bone cement compositions and/or their uses are discussed in U.S. Pat. No. 7,138,442; U.S. Pat. No. 7,160,932; U.S. Pat. No. 7,014,633; U.S. Pat. No. 6,752,863; U.S. Pat. No. 6,020,396; U.S. Pat. No. 5,902,839; U.S. Pat. No. 4,910,259; U.S. Pat. No. 5,276,070; U.S. Pat. No. 5,795,922; U.S. Pat. No. 5,650,108; U.S. Pat. No. 6,984,063; U.S. Pat. No. 4,588,583; U.S. Pat. No. 4,902,728; U.S. Pat. No. 5,797,873; U.S. Pat. No. 6,160,033; and EP 0 701 824, the disclosures of which are herein incorporated by reference.
The elastic moduli of typical PMMA bone cements lie around 2-4 GPa, while the elastic modulus of osteoporotic cancellous bone lies in the range of 0.1-0.5 GPa. This mismatch in stiffness is generally perceived as favoring the subsequent fracturing of the vertebral bodies that are adjacent to the augmented vertebral body.
It is therefore an object of the invention to obtain a bone cement with a reduced stiffness that is adapted to the stiffness of the surrounding bone. This is thought to be an efficient way to reduce the risk of adjacent vertebral body fractures after the augmentation of vertebral bodies.
Reduction of the stiffness by introducing non-miscible phases, such as aqueous
components, into the PMMA upon polymerization is well known and has been described before. This leads to a macroporous structure with reduced stiffness.
SUMMARY OF THE INVENTION
The invention relates to a bone cement including a monomer and a substance that is substantially miscible with the monomer and substantially does not contribute to a polymerization reaction. In one embodiment of the invention, the substance is N-methyl-pyrrolidone. In another embodiment, the substance is dimethyl-sulfoxide (DMSO). In another embodiment, the substance is polyethylene glycolide (PEG). In another embodiment, the substance is cellulose and cellulose derivates. In another embodiment, the substance is a mixture or blend of the mentioned substances or other, comparable substances. In another embodiment, the substance reduces a crosslink density of the bone cement. In another embodiment, the substance creates a microporous structure in the bone cement. In another embodiment, the bone cement further includes polymerization of the monomer. In another embodiment, a portion of the monomer in substituted by the substance during polymerization. In another embodiment, substitution of the monomer by the substance yields a decrease in the stiffness of the bone cement.
The invention also relates to a bone cement including methyl-methacrylate and N-methyl-pyrrolidone. In one embodiment of the invention the volume percentage of the methyl-methacrylate which is substituted by NMP, DMSO, PEG or other analogous substances lies in the range of 20%-60%. One specific example includes a volume percentage substitution of 25%. The volume of MMA can be substituted by either one of the pure substances mentioned above or by a mixture of these substances. In another embodiment of the invention, a stiffness of the bone cement is between about 100 MPa to about 2000 MPa. In another embodiment of the invention, a stiffness of the bone cement is between about 100 MPa to about 1500 MPa. In another embodiment of the invention, a stiffness of the bone cement is between about 500 MPa to about 1200 MPa. In another embodiment of the invention, a yield strength of the bone cement is from about 30 MPa to about 100 MPa. In another embodiment of the invention, a yield strength of the bone cement is from about 30 MPa to about 80 MPa.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the stiffness and yield strength of bone cements according to an embodiment of the present invention;
FIG. 2 is a graph showing the hardening behavior of bone cements in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
The present invention relates to a polymer bone cement or a derivative thereof having improved mechanical properties that is adapted to bone or osteoporotic bone. In one embodiment of the invention, the polymer bone cement is PMMA. The improved mechanical properties are achieved by adding a fully miscible solvent that does not react with the PMMA to the reactive MMA monomer. By doing so, the crosslink density of the material and the stiffness can be reduced.
The present invention is based on using a substance that is fully miscible with the monomer and is, therefore, molecularly dissolved in the PMMA after polymerization. However, due to its non-reactivity, this leads to a reduction in the final crosslink density and/or to a material with a microporous structure and, therefore, the stiffness of the material is reduced. After implantation and full polymerization of the material, the crosslink-lowering substance may be gradually substituted by body fluids.
This concept was tested by substituting different amounts of the reactive monomer with N-methyl-pyrrolidone (NMP), which does not contribute to the polymerization reaction. Subsequent mechanical testing of PMMA samples produced in this way showed a reduction in stiffness greater than about 50% in some embodiments.
The described effect of lowering the stiffness of the material can be obtained with any solvent that is miscible with the monomer of PMMA but does not contribute to the polymerization reaction. Another example of such of a solvent is Dimethyl-sulfoxide (DMSO). In other embodiments, a range of other solvents can also be envisioned. In another embodiment, substances such as PEG, cellulose, cellulose derivates or mixtures thereof can be added.
Furthermore, the present concept is not limited to PMMA cements, it can be applied to a wide variety of derivatives of PMMA, e.g. modifications in which Styrene groups are built into the polymer backbone. The same concept also applies to cements that are not based on the acrylate chemistry.
A material as described above, with mechanical properties adapted to those of e.g. osteoporotic bone can be used in any indication, where bone needs to be augmented, e.g. the proximal femur, the proximal humerus, long bones, vertebral bodies or the like.
As shown by the data in Table 1, the bone cements according to embodiments of the present invention that include NMP exhibit a decrease in stiffness when compared to the bone cement without NMP. The decrease in stiffness occurs as a result of the substitution of some of MMA monomer by NMP. According to some embodiments, by substituting a part of the reactive liquid MMA monomer with non-reactive organic solvent NMP during polymerization, the crosslink density in the final material was lowered and therefore the stiffness of the material was reduced. In other embodiments, the NMP can act as a pore forming phase, resulting in bone cement having a microporous structure. As discussed above, a decrease in stiffness is an efficient way to reduce the risk of adjacent vertebral body fractures in vertebroplasty procedures.
In some embodiments, the bone cements including NMP demonstrate an increase in hardening time. That is, the time for the bone cement to set and harden is longer for the cements having an NMP component. In some embodiments, an increase in handling time allows for greater working time for the user, which can increase the safety of surgical procedures.
In addition to the reduced stiffness, another property which is influenced by the mentioned modification is the maximum polymerization temperature of the exothermic polymerization of PMMA. Typically, polymerization of the PMMA can generate enough heat and increase the temperature of the bone cement to such a degree as to cause tissue necrosis. Because the bone cements of the present invention includes a lower content of monomer (MMA), which is the component that generates the heat during the polymerization reaction, the maximum polymerization temperature can be lowered. This is particularly advantageous because tissue necrosis may be reduced or avoided when the bone cement of the present invention is used, which allows for the use of the bone cement in areas of the body which are particularly sensitive to heat. For example, bone necrosis or other tissue necrosis can be a substantial problem during cranial reconstruction where the bone cement may contact the dura mater, due to the delicacy of the tissues and bone structures. Use of a bone cement having reduced heat generation is therefore particularly desirable in these areas.
Another advantage of the bone cements of the present invention is the potential reduction in the toxicity of the composition. Bone cement monomers, including methyl methacrylate, give off toxic vapors which can be irritating to the eyes and respiratory system. Furthermore, acrylate monomers can irritate the skin, and contact with minute concentrations can cause sensitization. Therefore, since the bone cement of the present invention uses a lower amount of monomer, the potential for the above problems to occur while using the bone cement of the present invention may be reduced.
In some embodiments of the present invention, the bone cement can be useful for vertebroplasty. The mentioned properties of hardening behavior, mechanical and thermal properties especially increasing of the handling time (more time for the surgeon and therefore more safety), lowering the stiffness (avoiding the mechanical property mismatch of the bone to the cement) and reducing the polymerization temperature (reduce tissue necrosis) are important properties for cement used in vertebroplasty. It is possible, that all of these requirements could be achieved by substituting some of the MMA monomer with NMP.
Example
The following example was carried out using commercial PMMA cement Vertecem. Vertecem is a fast setting, radiopaque acrylic bone cement for use in percutaneous vertebroplasty. The fluid phase is composed of 97.6% methyl-methacrylate (MMA), 2.4% N, N-dimethyl-p-toluidine as activator and very small quantities (20 ppm) of hydroquinones as stabilizer. The polymer powder is composed of 64.4% PMMA, 0.6% benzoyl peroxide which initiates the polymerization, 25% barium sulfate as radiopaque agent and 10% hydroxyapatite.
The fluid MMA monomer phase was partly substituted by NMP organic solvent by different amounts. NMP is totally miscible with the MMA monomer fluid. The amounts of MMA, and NMP, and PMMA used in the different compositions are listed in Table 1.
TABLE 1
Sample
MMA/
NMP/
PMMA
Stiffness/
Yield Strength/
Name
ml
ml
Powder/g
MPa Average
MPa Average
0%
10
0
21
2384
78
20%
8
2
21
1838
86
30%
7
3
21
752
52
50%
5
5
21
456
37
60%
4
6
21
320
24
The MMA monomer and NMP was premixed to form a fluid mixture. Subsequently the fluid mixture was mixed with the PMMA powder to form a paste. To prepare the samples for mechanical testing, the paste was filled into cylindrical Teflon® molds (20 mm height, 6 mm diameter). The hardened cylinders were then removed from the mold, sawed and ground to the length of 12 mm, these dimensions correspond to the requirements of standard ISO 5833. After storing the samples in water for 6 days at room temperature they were submitted for mechanical compression testing according to standard ISO 5833. The elastic modulus and yield strength were determined according to the mentioned standard and presented in FIG. 1 . Results are shown in FIG. 1 , illustrating trends versus percent of MMA that is substituted by NMP.
For the investigation of the hardening behavior of the cement compositions, 3 ml of the mixed bone cement were placed in a rotational rheometer with a custom designed double gap measurement system and rheological data were recorded directly to a computer for 24 portions of cement. The real (fluid-like) part of complex viscosity vs. time data are presented in FIG. 2 . | A bone cement is shown that includes a monomer, and a non-reactive substance that is fully miscible with the monomer. A resulting cured bone cement exhibits desirable properties such as modification in a stiffness of the material. Modified properties such a stiffness can be tailored to match bone properties and reduce an occurrence of fractures adjacent to a region repaired with bone cement. One example includes adjacent vertebral body fractures in vertebroplasty procedures. | 0 |
RELATED APPLICATIONS
This application is a division of application Ser. No. 640,945, filed Dec. 5, 1975, and entitled INLAY WHEEL AND METHOD (now U.S. Pat. No. 4,043,152 issued Aug. 23, 1977.
BACKGROUND OF THE INVENTION
The majority of double knit machines in existence today are fine gauge machines and more particularly 18 gauge machines. These machines were used to knit the majority of the double knit fabrics used in making slacks and trousers for ladies and gentlemen. But today many of these 18 gauge machines stand idle because of decreased demand for the fabric customarily produced on these machine.
Recently, there has appeared an apparatus utilizing a wheel for inlaying a yarn into fabric being knit on a double knit machine. See British Pat. No. 1,382,286 published Jan. 29, 1975. The inlay wheel in said British Patent comprises a shaft with a drive gear fixed to one end and a plurality of vanes fixed to the other end, each of which successively registers with the space between two adjacent needles in either the dial or cylinder bed, as desired. The drive gear has teeth which mesh with the stems or needles as the needle bed rotates in a conventional manner during knitting. Engagement of successive needle stems with the drive gear on the inlay wheel causes the inlay wheel to rotate on its shaft in the same direction as its associated needle bed and present successive vanes to the needle bed which register with the spaces between successive pairs of adjacent needles. The inlay yarn is trained circumferentially around successive vanes on one side of the inlay wheel and the vanes lay the inlay yarn on selected needles advanced to the tuck position and beneath other needles retained in welt position. The rotation of the inlay wheel delivers the inlay yarn to the needle bed and it is the correspondence in spacing of the gear teeth and the stems of the needles that causes the inlay wheel to rotate and deliver the inlay yarn to selected needles preparatory to being laid in the fabric.
Difficulty has been experienced in the use of the needle stems to rotate the inlay wheel because the critical correlation of spacing between the vanes and the spacing between needles in the needle bed is not reliably maintained; that is the rotation of the vanes on the inlay wheel is not reliably synchronized with the rotation of the dial. Consequently, the vanes sometimes hit the needles instead of meshing with the space between adjacent needles, causing a smash-up.
According to the invention, selected needles are removed (preferably alternate needles to half gauge the machine) to accommodate the inlay of coarse yarn, and the removed needles are replaced with drive elements which provide improved means to rotate the vanes of the inlay wheel in reliably precise synchronization with the rotation of the needle bed. The drive elements are of sturdier stock than the delicate needle stems used in the prior art to impart rotation to the drive gear and the drive elements are provided with butts so as to be under control of the needle cams but the drive elements do not have hooks or latches and play no part in knitting. The drive elements directly contact the vanes to impart rotational movement thereto as the needle bed rotates so that the separate gear of the prior art is eliminated.
The use of the inlay wheel in combination with the novel drive elements enables the production of a novel .[.two.]. .Iadd.fine .Iaddend.gauge ground or body yarn and the surface side is apparently formed of a heavy or coarse gauge yarn; although in reality the heavy yarn is laid in spaced courses and tightly locked in place by stitches of the ground yarn.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a serviceable and decorative multi-gauge fabric .[.or.]. .Iadd.of .Iaddend.novel construction on a conventional fine gauge double knit machine.
It is another object of the invention to provide a novel method and apparatus for producing said fabric on said machine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view, partially in elevation, of fragments of the dial and needle cylinder of a double knit machine and an associated inlay wheel,
FIG. 2 is a view similar to FIG. 1 but looking at the right side of FIG. 1 and showing the novel drive elements which replace alternate dial needles after the dial has been half-gauged;
FIG. 3 is .[.an enlarged.]. .Iadd.a somewhat schematic perspective .Iaddend.view of the inlay wheel in use; .[.and illustrating its relevant spacing to the knitting needles and drive elements.].
FIG. 4 is an elevation of a drive element of this invention removed from the machine;
FIG. 4A is an elevation of a prior art knitting needle removed from the machine;
FIG. 5 is a view similar to FIG. 1 but in elevation;
FIG. 6 is a diagram of a first inlay construction;
FIG. 7 is a stitch construction according to the diagram of FIG. 6; and
FIGS. 8 and 9 are diagrams of alternate inlay constructions within the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the drawings, the numeral 10 broadly designates the dial of a double knit machine having a plurality of radially extending grooves or tricks 11 within each of which conventionally radially reciprocable dial knitting needles 12. The machine also conventionally includes a needle cylinder 13 having vertically reciprocable needles 25 whose configuration is the same as the dial needles 12. In the illustrated embodiment, an inlay wheel 15 is associated with the dial 10. The usual form of camming arrangement is provided for operating the dial and cylinder needles, and the usual feed stations are circumferentially spaced around the machine from each of which fabric 14 extends.
It will be understood that the inlay wheel 15 may be associated with the cylinder of the machine and whereas in the construction shown in the drawings the dial and cylinder rotate, these parts may be fixed and the cylinder cam box and the dial cap rotated.
The attachment 15 includes a frame B which is adapted to be secured to the dial cap (not shown). The frame mounts a spindle 17 on which is mounted the inlay wheel 15 having on its periphery, circumferentially spaced and radially extending vanes or blades 20. The circumferential spacing of the blades 20 is approximately the width of two adjacent grooves 11. Thus, as most clearly seen in FIG. 2, adjacent blades 20 straddle adjacent grooves 11. Each blade is provided at its outer end with a V-shaped recess 21 to receive inlay yarn Y.
The frame mounts a yarn guide 16 for the inlay yarn Y and tensioning means (not shown) may be provided on the frame so that the tension of the inlay yarn may be adjusted. The guide 16 feeds the inlay yarn to V-shaped recesses 21 as best seen in FIGS. 1 and 5. The attachment is mounted intermediate a pair of thread feeds of the machine at a position which would normally be occupied by a thread feed so that there may be as many inlay attachments as there are thread feeds depending on the effect required in the finished fabric. In the illustrated embodiment, there is an inlay wheel attachment at every eighth feed, as is apparent from FIGS. 6-9.
According to the invention, selected needles are removed from the dial. This serves the dual purpose of providing additional space between dial knitting needles to accommodate a much coarser yarn than the body or ground yarn from which the fabric 14 is knit, and of providing space for the insertion of drive elements 30. In the illustrated embodiment alternate dial needles are removed so that the dial is half-gauged. A drive element is positioned in each of the vacant tricks or grooves 11 from which a dial needle has been removed. Each drive element 30 is dimensioned like the needle it replaces and includes butts 31 engagable with the conventional cams for actuating the elements 30 like the knitting needles during the knitting cycle. The drive elements 30 are under control of the conventional camming and are radially reciprocable within their respective grooves 11 according to a selected pattern. The drive elements differ from the knitting needles only in that the elements are slightly shorter than the needles, the elements do not have any hooks or latches and play no part in the formation of stitches, and the stem of the element is sturdier than the corresponding stem of the needle. The elements 30 function as spacers between needles and as drive members to engage the vanes 20 on the inlay wheel 15 responsive to rotation of the dial in a given direction indicated by the arrow D in FIG. 2. Engagement of vanes 20 by the driving elements 30 imparts rotation to the inlay wheel 15 in the same direction of movement as the dial 10.
Referring to FIG. 2, it will be observed that the peripheral spacing of the vanes 20 on the inlay wheel 15 coincides with the spacing between adjacent elements 30 in the dial 10, it being understood that there is a dial needle 12 between adjacent drive elements 30. Thus, in FIG. 2, it is shown that vane 20A is engaged by drive .[.elements.]. .Iadd.element .Iaddend.30A just before vane 20B will be engaged by driving element 30B.
With a mechanical set-up as described above, the dial and cylinder needles form the fabric 14 from body or ground yarn such as .[.15.]. .Iadd.75 .Iaddend.denier monofilament, for example. The fabric 14 may be of any desired construction such as Ponti Di Roma, Swiss .[.Bouque.]. .Iadd.Pique .Iaddend.or the like. A plurality of inlay wheels 15 are positioned about the circumference of the dial 10, there being an inlay wheel at every eighth feed in the described form of invention to inlay yarn Y at every eighth course of the fabric. The inlay yarn Y is of a higher .Iadd.denier .Iaddend.yarn such as, for example, 1500 denier and is locked to the fabric 14 formed from the .[.15.]. .Iadd.75 .Iaddend. denier ground yarn in such a way as to appear only on the front or surface side of the fabric. In the completed fabric the higher denier inlay yarn Y substantially obscures the fine denier body yarn on the surface of the fabric and gives the appearance the entire fabric is formed of heavy denier yarn when in fact the heavy denier yarn is only laid in every eight courses or more or less as desired.
The inlay yarn Y is locked into the fabric 14 by presenting it from the inlay wheel 15 to selected needles 12t in the tuck position while passing selected needles 12w in the welt position. As most clearly seen in FIG. 3, the selected needles in the tuck position are the alternate odd numbered needles and the selected needles in the welt position are the intervening even numbered needles.
According to FIGS. 6 and 7, the inlay yarn Y is layed on the alternate odd numbered dial needles 12(1), 12(3), 12(5) in tuck position and .[.floated across.]. .Iadd.beneath .Iaddend.the intervening .[.alternate.]. even numbered dial needles 12(2), 12(4), 12(6) in welt position and also .[.floated across.]. .Iadd.beneath .Iaddend.the space occupied by intervening drive elements 30. Consequently, in the illustrated embodiment of FIGS. 6 and 7 the inlay yarn Y is laid in every .Badd..[.4th.]..Baddend. .Iadd.8th .Iaddend.wale and .[.floated across.]. .Iadd.beneath .Iaddend.the .[.three.]. .Iadd.seven .Iaddend.intervening wales. .[., the alternate even numbered of every fourth wale being non-knit.]. The body yarn 29, according to FIGS. 6 and 7, is knit on .[.every.]. .Iadd.alternate odd numbered .Iaddend.cylinder .[.needle.]. .Iadd.needles (1), 25(3) and 25(5) .Iaddend.in the inlay course 1 and on alternate odd numbered dial needles .[.12.]. .Iadd.12(1), 12(3), 12(5) .Iaddend.in course 1. In course 2 of FIGS. 6 and 7 the body yarn 29 is knit on the .Iadd.even numbered .Iaddend.dial needles 12.Iadd.(2), 12(4), 12(6) .Iaddend..[.but is not knit.]. .Iadd.and .Iaddend.on .[.any.]. .Iadd.all .Iaddend.of the cylinder needles 25. .Iadd.Course 3 is produced on all the dial needles. The odd numbered dial needles 12(1), 12(3), 12(5) tuck the inlay yarn Y with their previously formed loops in course 1. This action moves the lay of the inlay yarn Y forward two courses within the fabric which effectively locks the inlay yarn Y within the structure of the fabric. .Iaddend. It is apparent from .[.FIG. 6.]. .Iadd.FIGS. 6 and 7 .Iaddend.that this arrangement results in the body yarn 29 being knit all around the inlay yarn Y when it is laid on the alternate odd numbered dial needles 12, that is it is confined between body yarn knit in .[.the same wale in adjacent courses.]. .Iadd.alternate dial wales of the same course .Iaddend.and between the body yarns knit in .[.adjacent wales in the same course.]. .Iadd.non-consecutive courses of the same wale. .Iaddend.
In the .[.alternate.]. .Iadd.alternative .Iaddend.inlay construction of FIG. 8, the inlay course is also represented at 1 and the inlay yarn Y is laid on the odd numbered dial needles 12.Iadd.(1), 12(3), 12(5) .Iaddend.in tuck position and .[.floated across.]. .Iadd.beneath .Iaddend.the intervening wales where the even numbered dial needles 12.Iadd.(2), 12(4), 12(6) .Iaddend.are in welt position. .[.As in FIG. 6 the.]. .Iadd.The .Iaddend.body yarn 29 is knit on all the cylinder needles in course 1 and on the odd numbered alternate dial needles 12. In FIG. 8, however, the inlay yarn Y is locked in position by knitting the body yarn 29 on the same dial needles 12 in course .[.2.]. .Iadd.4 .Iaddend.of FIG. 8.
The construction of FIG. 9 .[.is similar to FIG. 8, the only difference occurring in courses 2 and 6. Courses 2 and 6 of FIG. 9 are the same as the corresponding courses in FIG. 6, where the ground yarn is not knit on the cylinder needles, but is knit on all the dial needles..]. .Iadd.lays yarn in every fourth course, alternate inlay yarns Y being laid on the even numbered dial needles 12(2), 12(4), 12(6) and intervening inlay yarns Y 1 being laid on the odd numbered dial needles 12(1), 12(3), 12(5). The body yarn 29 is knit on corresponding dial needles in respective inlay courses and on the odd numbered cylinder needles in each inlay course. .Iaddend.
The drive elements 30 are indicated at X in the diagram of FIG. 6 and the effect of the drive elements 30 is shown by the non-knit area in every fourth wale of FIG. 7, there being three wales of knit construction between adjacent element wales.
There is thus provided a novel method of knitting on a conventional fine gauge double knit machine and the resulting fabric which includes a relatively course inlay yarn securely locked in and completely dominating the front or surface side of the fabric, to provide a highly ornamental and useful fabric. The scope of the invention is defined in the following claims. | A double knit fabric of a given gauge (usually fine gauge) is provided with an inlay of a coarser gauge yarn on a knitting machine with two needle beds. One side of the fabric is formed of only relativey fine gauge yarn and the relatively coarser inlay yarn is confined to the other or surface side of the fabric. Selected needles in one of the needle beds are replaced by drive elements. The inlay yarn is laid in by an inlay wheel driven in synchronization with the needle bed by said drive elements. | 3 |
BACKGROUND
1. Technical Field
The description relates to techniques for designing on-chip systems.
One or more embodiments may apply to Network-on-Chip (NoC) interconnects, e.g., for System-on-Chip (SoC) arrangements.
One or more embodiments may provide a scalable and distributed approach to perform traffic routing in hierarchical interconnects, possibly by resorting to an architecture for a scalable SoC source map.
2. Description of the Related Art
Time-to-market is a factor increasingly dictating the success of modern and complex SoC products, such as application processors for mobile and multimedia applications (smartphone/tablet, Set-Top Box, Home Gateway, and so on).
So-called “platforms” are thus increasingly resorted to in order to facilitate the creation of different SoC products (derivatives) for different market segments.
A “platform” is a system which may be used, e.g., to prototype a System-on-Chip design.
Certain platform embodiments as disclosed, e.g., in EP 2 325 747 A2 may include an electronic board comprising a logic device programmable to emulate system components and a processor to execute a virtual machine monitor which redirects an input/output request to the system components via an interconnect.
It was observed that embodiments of a platform may rely on a certain architecture and a related methodology which may take advantage of common features of different SoC products to reduce the development cycle and facilitate software portability from one derivative to another.
Design and verification of, e.g., a silicon interconnect is often a time-consuming task which drastically affects time-to-market of products. This may be even more evident in a platform context when attempting to derive derivative interconnects from a common and generic interconnect.
Various embodiments may thus benefit from the possibility that a certain interconnect may be customized for various derivatives. However, different derivatives may have different underlying physical constrains, which may render interconnect re-usage difficult (if at all feasible).
It was observed that when trying to adapt a generic interconnect to a derivative one, a good deal of time may be devoted to reworking the Source Map. The Source Map provides the information for routing response transactions from slave IPs to master IPs (that initiate request transactions towards slave IPs). While the relative cost may be acceptable for certain embodiments, the possibility of avoiding such re-working activity may contribute to making the platform approach more efficient by reducing costs and development time.
BRIEF SUMMARY
Various embodiments of a platform may thus rely on generic and re-usable components, a case in point being represented by an interconnect bus which may be re-used in a set of derivative products. In order to comply with such a requirement, the need is felt for interconnect arrangements which may be rendered “agnostic” to physical constraints (e.g., floorplan, pad distribution, etc.), which may represent a relevant cost in terms of design and verification tasks.
One or more embodiments have the object of satisfying such a need.
One or more embodiments achieve that object by means of a system having the features set forth in the claims that follow.
The claims are an integral part of the technical teaching provided herein in relation with one or more embodiments.
One or more embodiments may overcome the limitations of various embodiments by means of a NoC architecture built as a collection of independent units (sub-networks).
One or more embodiments may be applied to System-on-Chip (SoC) products.
One or more embodiments may be applied, e.g., to SoC products embedding at least a host CPU and multiple IP components (i.e., IP cores) communicating between them and/or sharing resources such as on-chip memories, external DDR memories, on-chip infrastructure, etc.
One or more embodiments may adopt an approach where:
a SoC Network on Chip (NoC) interconnect may be provided as a collection of independent sub-networks; the possibility may exist of expanding existing interconnects without impacting already existing ones; each NoC sub-network may be agnostic to the SoC source (src) map.
One or more embodiments may provide one or more of the following advantages:
reduced silicon development time, e.g., in a platform context; interconnect re-spin no longer needed when deriving multiple SoCs from a same platform; the Source Map may be independent from SoC physical constraints, e.g., each sub-network may have a source map that is independent from the interconnect in which it will used.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Non-limiting and non-exhaustive embodiments are described with reference to the following drawings, wherein like labels refer to like parts throughout the various views unless otherwise specified. One or more embodiments will now be described, purely by way of non-limiting example, with reference to the annexed figures, wherein:
FIG. 1 is a schematic block diagram representative of embodiments of an exemplary platform;
FIG. 2 represents a possible exemplary change in the platform of FIG. 1 ;
FIGS. 3 and 4 represent certain possible details of the platform of FIGS. 1 and 2 ;
FIGS. 5 to 7 exemplify certain features of embodiments;
FIG. 8 exemplifies a first option for possible embodiments; and
FIGS. 9 and 10 , this latter figure including three portions designated a), b) and c), respectively, exemplifies a second option for possible embodiments.
DETAILED DESCRIPTION
In the ensuing description one or more specific details are illustrated, aimed at providing an in-depth understanding of examples of embodiments. The embodiments may be obtained without one or more of the specific details, or with other methods, components, materials, etc. In other cases, known structures, materials, or operations are not illustrated or described in detail so that certain aspects of embodiments will not be obscured. Reference to “one or more embodiments” in the framework of the present description is intended to indicate that a particular configuration, structure, or characteristic described in relation to the embodiment is comprised in at least one embodiment. Hence, phrases such as “in an embodiment” or “in one embodiment” that may be present in one or more points of the present description do not necessarily refer to one and the same embodiment. Moreover, particular conformations, structures, or characteristics may be combined in any adequate way in one or more embodiments.
The references used herein are provided merely for the convenience and hence do not define the scope of protection or the scope of the embodiments.
FIGS. 1 and 2 are generally exemplary of a “platform”, i.e., a system architecture 10 adapted to produce, e.g., a Network on Chip or NoC interconnect arrangement by relying on generic and re-usable components, so that the relative interconnect may be re-used in a set of derivative products.
In one or more embodiments the platform 10 may be based on a modular approach and thus include:
a main backbone 12 , and a set of functional clusters 16 .
In one or more embodiments, the platform may be configured to cooperate with entities such as memories indicated DDR (e.g., DDR memories) and/or boot devices BD.
To that effect, in one or more embodiments the main configurable backbone 12 may include modules or functions such as, e.g.:
Test— 120
Clock generator— 122
DDR control— 124 (e.g., 0 to 3 for controlling 4 DDRs)
Central Processing Unit or CPU system— 126
Graphics Processing Unit or GPU system— 128
CPU NoC— 130
Debug & Trace— 132
Direct Memory Access or DMA— 134
Security— 136
Power Management or PMU— 138
Sensor(s)— 140
Boot Device Control— 142
Audio— 144
Main NoC— 146 .
In one or more embodiments, the arrangement of each and every unit/function as per the exemplary, non-limiting list provided in the foregoing, may be per se conventional.
In one or more embodiments, the main backbone 12 may be made configurable, e.g., with possible simplification and customization, e.g., at the DDR, interconnect, GPU, clocking level.
In one or more embodiments, the main backbone 12 , e.g., the main NoC 146 may include a set of ports 15 .
In one or more embodiments, the functional clusters 16 may be attached to any of the backbone ports 15 .
In one or more embodiments, the functional clusters 16 may include modules or functions such as, e.g.:
a respective sub-network (sub-NoC) 160 adapted to act as an interconnect unit to the backbone port 15 in the main NoC 146 , Test Equipment 162 a set of IP's 164 , 166 additional modules/functions 168 , possibly adapted to interface with further associated modules/functions 170 to be attached to a cluster 16 .
As used herein, reference to a “respective” sub-network 160 is intended to highlight that, in one or more embodiments, one such sub-network 160 may be provided for each one of the functional clusters 16 .
Exemplary of modules or functions as per the non-limiting list provided in the foregoing may be transport, 3D GPU, video codec(s), 2D graphics, camera, networking, composition & display, high-speed links.
In one or more embodiments, the functional clusters 16 may be independent of the source map of the platform.
In one or more embodiments, each functional cluster 16 may be asynchronous to the other functional clusters 16 .
In one or more embodiments, a set of SoCs may be created by using a same platform by constructing them by using the functional clusters 16 as building-elements.
In one or more embodiments, the functional clusters 16 may have a granularity beyond the one of a IP (e.g., a functional cluster may be an aggregation of IPs that all together offer a given SoC function).
This may result in an incremental approach from an existing configuration by effecting steps such as, e.g., add/remove/move features, . . . , which, e.g., may be flexible enough to accept late requests without impacting the construction.
In one or more embodiments, the functional clusters (building elements) 16 may be “agnostic” to the other homologous elements in terms of source map and Network-on-Chip, which may permit construction of a new SoC or modification of an existing SoC by putting together (composing) these elements without impacting globally an already existing structure. This is in contrast with conventional SoC development approaches, where adding or removing an IP may impact the SoC infrastructure, e.g., on an interconnect arrangement designed with a global end-to-end view of a system.
A module architecture as exemplified in FIG. 1 may permit any functional move among the functional clusters 16 , including possible removal-and-move actions whereby any functional cluster 16 may be detached from main backbone 12 , e.g., the main NoC 146 , and made so-to-say subservient to another functional cluster as schematically represented in FIG. 2 .
Such an action is exemplary of the possibility of using the functional clusters 16 as building elements adapted to be shared across different derivative SoCs, thus permitting, e.g., re-usable hardware integration.
One or more embodiments may rely on a SoC interconnect construction wherein the SoC Network on Chip or NoC interconnect is a collection of independent sub-networks that offer the ability to expand existing interconnects without impacting the already existing one, wherein each NoC sub-network is, e.g., agnostic to the SoC source (src) map.
FIG. 3 is a schematic representation of an exemplary sub-network ( 160 in FIGS. 1 and 2 ) adapted to operate as an interconnect unit dedicated to a functional cluster 16 .
In one or more embodiments such a sub-network 160 may include one or more of:
a set of master ports M0, M1, . . . , Mn for use by IPs IP0, IP1, IPn (see e.g., 164 , 166 in FIGS. 1 and 2 ) located in the functional cluster 16 ; a master port SAP/Mext for connection (e.g., through SAP) to other sub-networks 160 ; a set of slave ports SP1, SP2, . . . for connection to the main backbone or other sub-networks: these slave ports may possibly include first slave ports (e.g., SAP) for connection to other functional clusters (FCs) and/or the backbone and second “normal” slave ports for connection with IPs (modules) within a functional cluster; a slave port Sn connected for accessing internal targets of the functional cluster.
The acronym SAP repeatedly used throughout this description stands for Service Access Point.
FIG. 4 is a schematic representation of an exemplary backbone ( 146 in FIGS. 1 and 2 ), that may also include a sub-network adapted to provide a NoC infrastructure that may cover “physically” the overall SoC floorplan
In one or more embodiments such a sub-network may provide the following functions/services:
connection (e.g., via SAP) to the different sub-networks 160 of functional clusters 16 ; slave ports, e.g., S0, S1, S2 for connection to main SoC targets (DDR), for instance in order to carry high-bandwidth traffic (e.g., to external DDRs, e.g., DDR0, DDR1, DDR2).
As exemplified in FIGS. 5 to 7 , one or more embodiments may also offer one or more of the following:
i) the ability to chain independent functional clusters 16 to a certain backbone 12 via the respective sub-networks 146 and 160 ( FIG. 5 ) ii) the ability to connect any of the sub-networks 160 , e.g., in the independent functional clusters 16 to any SAP of the backbone NoC or any other sub-network ( FIG. 6 ): iii) the ability to move a sub-network from a SAP of the backbone NoC to another one i.e., disconnect and reconnect ( FIG. 7 ).
One or more embodiments may adopt one of at least two different options in order to implement the functions exemplified in the foregoing.
A first option, discussed in the following with reference to FIG. 8 , may use an associative memory of the CAM (Content Addressable Memory) type with a number of locations which equals an upper threshold (e.g., the maximum) number of transactions which may be outstanding.
A second option, discussed in the following with reference to FIGS. 9 and 10 , may adopt an offset adding strategy, which makes it possible to use a memory having a number of locations equal to the number of initiator gates; this may be accessed by way of response by using a key which contains a source code (L2 SRC) received together with the response transaction.
In one or more embodiments, the first option for constructing the interconnect may rely on a layered source map-based architecture.
In one or more embodiments, each sub-network (e.g., the sub-NoC 160 in the functional clusters 16 ) in such an architecture may have a local independent source map.
Assuming that:
L1-SRC is a first information element or item which denotes a source managed locally by each sub-network, and L2-SRC is a second information element or item which denotes a SoC source that identifies univocally each SoC master
one may assume that each SAP of the sub-network will manage only one source value.
In one or more embodiments, this may ensure the independency of each sub-network, e.g., by making a sub-network “agnostic” towards the SRC requirements of the masters that are connected to it.
In one or more embodiments, a new field designated, e.g., L2SRC may be added to a NoC header in order to carry the L2-SRC information.
In one or more embodiments, the L1-SRC information may be stored in each sub-network i.e., SAP.
As exemplified in FIG. 8 , such an approach may involve two sub-networks 160 a and 160 b , the one ( 160 a =SN0) including two routers R10, R11 and the other ( 160 b =SN1) including one router R20.
In one or more embodiments, the sub-network 160 a (SN0) may manage via respective SAP modules, e.g., four (master) IPs M0, M1, M2, M3 each having a number of L2-SRC values.
In one or more embodiments, the L1-SRC SN0 may be used to manage the local sub-network reception (RX) routing, while the L2-SRC may be just carried in the NoC header and the L1-SRC SN0 may be stored in the SN0.
In one or more embodiments, the sub-network 160 a (SN0) and sub-network 160 b (SN1) may communicate via respective SAP modules.
In one or more embodiments, The L1-SRC SN1 may be used to manage the local sub-network reception (RX) routing, while again the L2-SRC may be just carried in the NoC header and the L1-SRC SN1 may be stored in the SN0.
In one or more embodiments, the sub-network 160 b (SN1) may manage via respective SAP modules, e.g., two (slave) IPs S0 and S1.
In one or more embodiments, this approach may implement a local source map L1 for each sub-network and a global source map L2 thus permitting to build a SoC interconnect for all derivative interconnects without re-designing any part of it (e.g., sub-networks can simply be re-used and chained together in order to meet functional and physical constraints of each SoC).
In a first option as exemplified in the foregoing, the L1-SRC information may be stored in a sub-network. Such a task may be performed, e.g., in a Target Network Interface (TNI) at the output of each sub-network (SN) by employing a Contents Addressable Memory (CAM) memory.
In one or more embodiments, the depth of such a memory may correspond to an upper threshold (e.g., the maximum) number of transactions that can be outstanding (from a TNI point of view).
Each location in a CAM may thus store a L1-SRC, L2-SRC pair associated to a transaction so that, when a response transaction is back to the TNI, the L2-SRC may be used as key to perform the search in the CAM.
In one or more embodiments, another transaction identifier may be stored in a CAM in the place of the L2-SRC information (which may depend, e.g., on a particular protocol, ordering model, and so on.).
One or more embodiments may adopt a second option, which may be particularly suitable when the number of transactions that can be outstanding is high and the cost of implementing a CAM having a large number of locations would be difficult to meet due to silicon area constraints.
In one or more embodiments, a general idea behind such an option would be to build a system in such a way to have by construction a single L2-SRC range for each master port in all the sub-networks. As used herein, “single range” would apply, e.g., to contiguous (adjacent) L2-SRC values.
By resorting to such an approach, the mapping L2-SRC<→L1-SRC in a sub-network may be handled with simple memory, i.e., a table having a number of rows equal to the number of master ports.
A mechanism to dynamically fill such a table (Dynamic Source Table or DST) may be used in order to make sub-networks usable in any context of interest (which may be a requirement for the platform based approach).
In one or more embodiments, building a system in order to have by construction a single L2-SRC range may involve updating a L2-SRC:
by adding an offset in request at the input of a sub-network (SN), and by subtracting a same offset in response at the output of a SN.
The block diagram of FIG. 9 illustrates an example of a N×2 sub-network 160 c where an offset, e.g., OS 0 , OS 1 , . . . , OS N is added to the L2-SRC of each initiator (or master) port M_Port0, M_Port1, . . . , M_PortN, of the sub-network.
While this is not expressly visible in the figure, a same offset may be subtracted in response at the initiator side.
As in the case of the first option discussed in the foregoing, in one or more embodiments, a routing within a sub-network SN may be by using a L1-SRC information, where the L1-SRC identifies an initiator port.
In one or more embodiments, offsets may be added by means of simple logic blocks (adders) 200 integrated when the SoC is designed.
In one or more embodiments, when sub-networks are integrated, proper offset values may be defined for each sub-network, e.g., by adopting an approach as exemplified in the following.
For instance, by assuming that for a certain sub-network or SN:
k is the index identifying an initiator port (i.e., L1-SRC) and OSk is the offset to be applied to the port k; Min_k and Max_k identify respective minimum and maximum L2-SRC values received on the port k (before applying the offset); Min_k′ and Max_k′ identify respective minimum and maximum L2-SRC values after the offset OSk has been applied,
then a value for OSk may be determined as follows:
If k= 0 =>OSk= 0
If k!= 0 =>OSk =Max_( k− 1)′−Min — k+ 1
(This means that, in one or more embodiments, the value for OSk may depend on the offset for an adjacent port).
Min — k ′ and Max — k ′ are then:
If k= 0=>No Offset is applied.
If k!= 0
Min — k ′=Min — k+OSk =Max_( k− 1)′+1
Max — k ′=Max — k+OSk =Max( k− 1)′+(Max — k −Min — k )+1
By adopting such an approach, a L2-SRC range associated to the target port of a sub-network SN (in output to a Target Network Interface or TNI) may be expressed as:
Target L 2-SRC→[Min — 0,Max_( N− 1)′+(Max — N −Min — N )+1]
where N identifies an upper threshold (e.g., the maximum) L1-SRC of the SN.
In one or more embodiments, such an approach may ensure that the L2-SRC range received in input to whatever port of whatever SN is a single range, regardless of how the sub-networks are connected.
In one or more embodiments, the L2-SRC range received in input to whatever port of whatever SN being single range regardless of how the sub-networks are connected may be exploited in order to handle the L1-SRC information by means of a simple table.
This is represented by way of example in FIG. 10 , which in portion a) refers again to a certain sub-network 160 c ; there, each block indicated as DST may be, e.g., a dynamically managed memory with N−1 locations, where N+1 is the number of initiator ports of the sub-network (i.e., the number of possible L1-SRC values).
In one or more embodiments, such a DST memory may instantiated for each target port (e.g., each Target Network Interface or TNI) of the sub-network.
In one or more embodiments, as exemplified in portion b) of FIG. 10 , each location in such a DST memory may include three fields, e.g.:
a L1 SRC field (which may not be an actual physical field, but just an the index or address of the location); a field for storing a Min L2-SRC value associated to a corresponding L1-SRC value; a field for storing a Max L2-SRC value associated to a corresponding L1-SRC value.
In one or more embodiments, such a table may be dynamically updated with a procedure whose basic rationale is that after an initial reset, a new request is waited for (e.g., no actions are taken as long as a no new requests are received) and, when a response is received, the L2-SRC value associated to that response is used as key to retrieve the L1-SRC to be used for the response routing in the SN.
The flowchart in portion c) of FIG. 10 illustrates an exemplary embodiment of such a procedure.
After reset, no actions are taken until a new request is received (“Wait for a new request”)—step 1000 .
When a new request is received, the proper table row is identified by using the L1-SRC as an index—step 1002 .
If the L2-SRC associated to the new request is smaller than the Min L2-SRC associated with the L1-SRC (positive outcome Y=Yes of a step 1004 ) the L2-SRC value is used as new Min L2-SRC—step 1006 , and processing returns upstream of the “wait” step 1000 .
If step 1004 yields a negative outcome (N=No), which is indicative of the L2-SRC associated to the new request being not smaller (e.g., equal or higher) than the Min L2-SRC associated with the L1-SRC, then a check is made in a step 1008 as to whether the L2-SRC is higher than the Max L2-SRC associated to the L1-SRC.
If the L2-SRC is higher than the Max L2-SRC associated with the L1-SRC (positive outcome Y=Yes of step 1008 ), the L2-SRC value is used as new Max L2-SRC, and processing returns upstream of the “wait” step 1000 .
If step 1008 yields a negative outcome (N=No), which is indicative of the L2-SRC associated with the new request being not higher (e.g., equal or smaller) than the Max L2-SRC associated with the L1-SRC processing returns upstream of the “wait” step 1000 .
This means that if the tests of steps 1004 and 1008 yield negative outcomes, in that neither of the respective conditions are true, no updates to the table are performed.
In one or more embodiments, when a response is received, the right table row may be identified by checking the condition:
Min L 2-SRC≦L2-SRC≦Max L 2-SRC
The index of the table row that satisfies this condition is the L1-SRC which may be used for the response routing in the sub-network; this task may be performed, e.g., by means of a comparator network.
One or more embodiments may offer one or more of the following advantages:
an ability to construct different interconnects of derivative SoCs belonging to a same platform by using the same building elements (e.g., the sub-networks of the functional clusters 16 ); a layered source map approach may permit to build derivative interconnects that are independent from physical constraints of different derivative SoCs (e.g., permitting chaining of sub-networks); low-cost solutions may become feasible by making use of a simplified memory (e.g., according to the second option discussed in the foregoing).
Without prejudice to the underlying principles of the invention, the details and embodiments may vary, even significantly, with respect to what is illustrated herein purely by way of non-limiting example, without thereby departing from the extent of protection. The extent of protection is determined by the claims that follow.
The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure. | A system for designing Network-on-Chip interconnect arrangements includes a Network-on-Chip backbone with a plurality of backbone ports and a set of functional clusters of aggregated IPs providing respective sets of System-on-Chip functions. The functional clusters include respective sub-networks attachable to any of the backbone ports and to any other functional cluster in the set of functional clusters independently of the source map of the Network-on-Chip backbone. | 6 |
FIELD OF THE INVENTION
This invention relates to a water and vapor barrier in an exterior insulation finish system.
BACKGROUND OF THE INVENTION
Exterior insulation finish systems (EIFS) are known in the art. Such systems typically consist of a layer of a substrate such as gypsum, an insulation layer (polystyrene, for example), mesh embedded in a coat of polymer and cement, and a polymeric finish. The polymeric finish can be applied in a variety of textures and colors to satisfy aesthetic requirements. Typical polymeric finishes comprise flexible acrylic latex compositions made by copolymerizing a high Tg monomer such as methylacrylate, ethyl acrylate, methyl methacrylate, etc. with a low Tg monomer such as butyl acrylate, hexyl acrylate, t-butyl acrylate, etc. These compositions are blended with sand to produce the finish. The mesh and polymer-modified cement layers can be applied in multiple layers.
Although such systems are said to be waterproof, problems are caused by water penetration through a variety of avenues such as cracks, joints and sealant failures. Problems include deterioration of the gypsum sheathing facer, loss of attachment of the system, corrosion or rotting of the structural members, spalling and delamination of the coatings and interior building damage. Where deterioration of the gypsum sheathing facer occurs, for example, the result can be the rotting of studs without any conspicuous signs of distress.
Care has been taken in the detailing of termination points such as sills, jambs, heads, parapets, scuffers, corners, and any opening or protrusion in an attempt to make them impervious to moisture. However, such detailing has proven time consuming and ineffective.
The use of waterproofing and vapor barrier membranes in interior insulation systems is known. The placement of the membrane is a function of the climate; the major consideration being that the dew point must occur where the resulting moisture condensation cannot penetrate the insulation. In cold climates, for example, the membrane is placed on the warm side of the insulation (i.e. between the insulation and interior finish) which prevents moisture condensation from penetrating the insulation. However, in regions where variations in climatic temperatures are significant, placement of the membrane to accommodate a colder exterior temperature will be inappropriate when the climate changes to warmer exterior temperatures. That is, in regions with varying climatic temperatures, the location where the dew point occurs and where the resulting moisture condensation forms in the building envelope varies. Heretofore, no suitable solution to the moisture condensation problem has been found.
U.S Pat. No. 3,411,256 discloses what is known in the art as an "upside down" roof. The upside down roof overcame the durability problems of the water impermeable membrane by adhering a layer of thermal insulation on the exterior side of the membrane. A protective layer is then employed to protect the insulating layer from sunlight. The protective layer can be water permeable.
U.S. Pat. No. 4,492,064 teaches a similar roof construction having channels to and in the evaporation of moisture through the insulation panels to the outside atmosphere. Thus disposed over a metal roofing deck is a fire-resistant barrier layer such as gypsum board, a water-permeable layer, a layer of thermal insulation material, and a water-permeable protective layer. The layer of insulation is unsecured to the water-permeable layer to allow for relative movement therebetween.
SUMMARY OF THE INVENTION
The problems of the prior art have been overcome by the instant invention, which provides a moisture and vapor barrier in an exterior insulation system. Specifically, the instant invention combines the EIFS with a two part membrane of multiple cross-laminated layers of polyethylene film, fully bonded to a layer of rubberized asphalt. Such a membrane is sold commercially under the trademark Perm-A-Barrier® by W. R. Grace & Co.-Conn. The membrane is positioned between the substrate and insulation layers of the EIFS. Thus, the exterior insulation system provides relative thermal stability to everything inside it, and allows for freer use of stud-line for plumbing and wiring, while the membrane provides air control through the wall assembly, and provides a water control mechanism for the wall assembly. Accordingly, numerous advantages are realized by the combination encompassed by the instant invention. The water-impermeable membrane acts as a vapor barrier and is strategically located so that the dew point of the air always occurs outside of the building, thereby eliminating moisture condensation problems. The water-impermeable membrane also serves to prevent water penetration into the building that would otherwise occur as a result of cracks, joints and sealant failures in the exterior insulation finish system, notwithstanding its water impermeability. In addition, the thermal insulation layer is mechanically fastened through the water-impermeable membrane to the substrate. The water-impermeable membrane is self-sealing, and therefore forms a seal around the fastening means to prevent water leakage. The use of the water-impermeable membrane between the gypsum board and insulationa eliminates the necessity of using exterior grade gypsum, and adds to the insulation value of the overall system by eliminating air movement in the form of draft.
It is therefore an object of the invention to provide moisture protection and water control in exterior insulation finish systems.
It is a further object of the invention to provide higher overall insulation effectiveness for exterior insulation finish systems.
A still further object of the invention is to provide a waterproofing, air barrier, vapor retarder layer in exterior insulation finish systems.
Another object of the invention is to provide waterproof details through the usage of a membrane system.
Yet another object of the invention is to provide a exterior insulation finish system for a building that insures that the dew point of the air occurs outside the building structure.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an expanded side view of an exterior insulation finish system including a water-permeable membrane in accordance with the present invention.
FIG. 2 an expanded side view of an exterior insulation finish system including a water-permeable membrane as applied to a foundation termination;
FIG. 3 is an expanded side view of an exterior insulation finish system including a water-permeable membrane as applied to an expansion joint;
FIG. 4 an expanded side view of an exterior insulation finish system including a water-permeable membrane as applied to a parapet;
FIG. 5 an expanded side view of an exterior insulation finish system including a water-permeable membrane as applied to a window head;
FIG. 6 an expanded side view of an exterior insulation finish including a water-permeable membrane as applied to a window jamb; and
FIG. 7 an expanded side view of an exterior insulation finish system including a water-permeable membrane as applied to a window sill.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is shown an exterior insulation finish system including a water-impermeable membrane in accordance with the instant invention. A structural strength (such as 18 gauge or heavier) light metal framing wall system utilizing a "C" stud 10 with existing cutouts 12 for in-wall plumbing and wiring (gauge and spacing to be determined in accordance with lateral load requirements, A.O.B.E.), to which is attached a 1/2 "thick gypsum drywall board 14 to the building exterior side of the stud, by means of appropriate size and type mechanical fasteners 16. To the exterior surface of the gypsum drywall board is applied the in-wall air, water, and vapor barrier membrane 18 such that the complete exterior surface of the building (excluding glass surfaces or architectural openings such as door and windows) shall be covered by this membrane, or is connected to a suitable material such that a continuous air, water, and vapor barrier is in place around the entire exterior perimeter of the building, including the roof. To the exterior of the in-wall membrane 18 shall be applied the mechanically attached exterior wall insulation 20 by means of fasteners 22, and the remainder of the finishing system 24, 26, or a modified version, thereof, which will be adapted to reflect the presence of the waterproofing membrane beneath. Suitable exterior wall insulation materials include cellular plastic foams, preferably extruded or expanded polystyrene foam. The remainder of the finishing system includes a water-impermeable polymer-based layer such as an acrylic-based system, preferably comprising blends of sand or quartz with acrylic copolymer latexes.
FIGS. 2-7 illustrate the system of the instant invention as applied to various termination points, etc. Specifically, FIG. 2 shows the system in the context of a foundation termination. In this embodiment, a provision is made for the release of water that might get behind the insulation layer 20 through defects in the exterior finish 24. To this end, flashing material means 28 is attached to the vapor barrier membrane 18 with a suitable sealant 32 and extends through the insulation layer 20 and the exterior finish 24. Exterior grade counter-flashing material means 29 is attached t the outer side of the insulation layer 20 by suitable means, such as mechanical fastener 30, and extends through the exterior finish 24 so as to define a weep hole 40 with said flashing 28. The flashing is shaped such that it is unlikely that water would enter the system at a weep hole. Suitable flashing materials include metal, or the membrane itself.
As with the embodiment illustrated in FIG. 1, gypsum board 14 or the like is attached to stud 10 by mechanical fasteners 16. Here, however, both the board 14 and stud 10 sit on the foundation 35. A suitable sealant 32 such as elastomeric sealants, including rubberized asphalt mastic or urethane elastomers, seals any cracks between the board 14 and foundation 35. A water-impermeable membrane 18 is applied to the exterior side of the gypsum board 14 and extend at least partially down the foundation 35. A suitable sealant 32 seals the membrane 18 to the foundation 35 where the membrane 18 terminates. An insulation layer 20 is attached to the exterior side of the membrane 18 by fastening means such as mechanical fasteners 22. The fasteners 22 extend through the membrane 18 which is self-sealing so as to form a water-impermeable seal around the fastening means. The fastening means can extend through the board 14 into stud 10. The exterior finish 24 is applied to the insulation layer in a conventional fashion. The insulation layer 20 and exterior finish 24 are discontinuous to provide for weep hole 40. The weep hole 40 must be located above grade level, and is preferably located just above the foundation termination and at window/door heads.
FIG. 3 depicts the exterior insulation finish system and membrane of the instant invention as applied to an expansion joint. A backer rod 49 sits in joint 52 between metal studs 10 and 10'. Gypsum board 14 is attached to the stud 10, and a suitable sealant 32 is applied in joint 52 at board 14 and extends to backer rod 49. In this embodiment, a plurality of membrane layers are used to provide moisture impermeability around the joint, while allowing the joint to expand and contract. A first layer 55 is installed over joint 52 as a cover in an inverted manner, i.e., with the rubberized asphalt surface being the exterior side so as to abut the rubberized asphalt surface of a second layer 56 which overlaps the first and the joint 52. The first layer 55 is inverted so that it remains unadhered and can flex as the joint expands and contracts. Similarly, the second layer 56 is not fully adhered. A third layer 18 is applied in accordance with the previous embodiments so as to cover the length of gypsum board 14 and overlap the first and second membrane layers as well. A metal, plastic or sealant expansion joint cover 58 is attached to the system with metal or plastic expansion joint cover fastening means 59, and extends through the insulation layer 20 and exterior finish 24.
FIG. 4 shows the exterior insulation system and membrane of the instant invention forming a parapet cap. Gypsum board 14 is placed around stud 10 and fastened with fastening means 16. Membrane 18 covers the board 14 around stud 10 and under roof system 65 and extends onto roof deck 60. The insulation layer 20 is then attached as shown to extend partially over roof system 65. The exterior finish layer 24 is applied in a conventional manner contiguous to the insulation layer 20
FIG. 5 shows the exterior insulation finish system and membrane of the instant invention as applied to a window head. As with the foundation termination embodiment, provision is made for the release of moisture from behind the insulation layer. Here the membrane 18 extends under board 14 and stud 10 between the board 14 and stud 10 and the window head 70 Sealant 32 is applied where the membrane 18 terminates at the stud 10, and also between window head 70 and backer rod 49. First flashing means 27 is attached through the membrane 18 by fastening means 50. Second flashing means 28 is attached through the insulation layer 20 by similar means 51 and together with flashing means 28 is suitably shaped to form weep hole 40 to allow moisture that has accumulated behind the insulation above the window head level to be vented from the wall before it reaches the window where the risk of water entry and/or damage is at a maximum. Suitable flashing materials include meral, or the membrane itself.
FIG. 6 illustrates the exterior insulation finish system and membrane of the instant invention as applied to a window jamb 75. As with the window head embodiment, the membrane 18 extends under the stud 10 and board 14 and is sealed to the stud at its termination point, and to the jamb 75. Insulation layer 20 and exterior finish 24 are attached as previously described.
FIG. 7 shows the exterior insulation finish system and membrane of the instant invention as applied to a window sill. The membrane 18 is attached to the board 14 and extends over the board 14 and stud 10 under the sill 80. A sealant 32 seals the membrane as its end. An L-shaped window sill flange 85 is mechanically fastened with fastening means 87 to the stud 10. The insulation layer 20 and exterior finish 24 are placed in sequence as before. | A new concept wall system is provided, wherein a moisture and vapor barrier is positioned in an enterior insulation finish system to provide thermal stability regardless of climatic variations. Specifically, a two part membrane of multiple cross-laminated layers of polyethylene film fully bonded to a layer of rubberized asphalt is placed between the substrate and insulation layers of the exterior insulation finish system. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to production outlets for large bore Christmas trees.
Traditionally, buoyant oil markets have provided the financial justification for the development of, and production from, multiple wells. However, current market circumstances dictate that whilst production volume must be maintained, it must be done with a reduced number of wells. This has led to the development of larger bore production xmas trees.
Large bore production xmas trees, particularly subsea trees utilizing horizontal outlets, present problems with outlet diameters. Current outlet valve technology accommodates outlets of up to 7″ (178 mm) diameter. Any production outlet with a diameter of over 7″ (178 mm) will require the development of a new subsea gate valve, with the consequent costs involved, as well as the disadvantages of increased size and weight of the new design.
SUMMARY OF THE INVENTION
The present invention solves the above problems by enabling the use of existing standard sized outlet valves and actuators in a large bore production tree. To that end, the present invention provides a production Christmas tree having multiple production outlets extending from a single production bore. Splitting one large production outlet into two or more smaller outlets allows the use of existing subsea gate valves and actuators, with each production outlet being controlled by a separate, standard sized valve, thereby avoiding the cost of development of a new larger subsea gate valve. This system has the further benefit that pressure drops due to reservoir depletion, and associated flow assurance problems, can be alleviated by closing one of the production outlets. Erosion problems are also reduced. Preferably each production outlet has a different diameter. By selecting different outlets or combinations of outlets, a wide range of production flow rates can be catered for, as the reservoir pressure drops over the lifecycle of the field. In a preferred embodiment, two outlets are provided. These may be for example a 7″ (178 mm) and a 5″ (127 mm) outlet. However other diameters may be used, for example to suit smaller sized valves.
An illustrative embodiment of the invention is described below with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows the vertical bore and single horizontal production outlet of a prior art large bore horizontal production tree; and
FIG. 2 schematically shows a dual production outlet horizontal tree embodying the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The prior art horizontal xmas tree shown in FIG. 1 has a vertical through bore 10 and a single horizontal production outlet 12 branched off from the vertical bore 10 . Annular seals 14 , 16 surround the vertical bore 10 above and below the production outlet 12 , to seal a tubing hanger (not shown) in the vertical bore 10 , as is conventional. A gate valve 18 forming a production master valve is situated in the production outlet 12 .
The embodiment of the invention shown in FIG. 2 is similar, except that the horizontal outlet 12 from the production bore is split into two separate outlets 20 , 22 . One of these outlets 20 is controlled by a 5″ (127 mm) subsea gate valve 24 and actuator. The other outlet 22 is controlled by a 7″ (178 mm) subsea gate valve 26 and actuator. Other multiple outlet configurations will be readily apparent, for example having other diameters to suit other anticipated production flow rates, or including three or more separate outlets, each controlled by an appropriately sized valve. Although gate valves are generally preferred, other forms of valve may be suitable in particular circumstances. The xmas tree of the invention may also incorporate other features known in prior xmas trees, for example an annulus and/or workover conduit, and a crossover conduit extending between the annulus/workover conduit and one or more of the production outlets. These additional conduits (shown in dotted lines in FIG. 2 ) will be controlled by suitable valves, as is conventional.
It should be recognized that, while the present invention has been described in relation to the preferred embodiments thereof, those skilled in the art may develop a wide variation of structural and operational details without departing from the principles of the invention. Therefore, the appended claims are to be construed to cover all equivalents falling within the true scope and spirit of the invention. | A large bore Christmas tree includes a production outlet that is split into multiple separate outlets, each controlled by a separate, standard sized valve and valve actuator. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present invention employs some of the matter disclosed and claimed in commonly owned copending applications filed on even date herewith by Willenbecher et al, Ser. No. 684,036, entitled SPEED-RELATED INDICATION COMPARISONS IN INTERNAL COMBUSTION ENGINE DIAGNOSTICS; by Rackliffe et al, Ser. No. 684,220, entitled SUB-CYCLIC MEASUREMENT OF SPEED OF AN INTERNAL COMBUSTION ENGINE; and by Stick et al, Ser. No. 684,037, entitled DETERMINATION OF NUMBER OF TEETH ON AN INTERNAL COMBUSTION ENGINE FLYWHEEL.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to diagnosing internal combustion engines electronically.
2. Description of the Prior Art
One of the subsystems on a vehicle mounted engine which is critical to continuing engine health is the cooling system. In diesel engines, coolant must flow adjacent the cylinder jackets or the engine will disintegrate quite rapidly. The water temperature does not get too hot, so a very primary concern is the condition of the coolant pump; that is, is the coolant pump healthy and does it deliver a suitable mass flow rate of coolant at a suitable pressure; and another primary concern is whether the coolant passages in the engine have become restricted. The principle tests for these conditions in the prior art is measuring pressure ratios across the pump and across the engine at specific speeds while the engine-related vehicle is loaded by a dynomometer. Obviously, the use of a dynomometer is not always possible; further, dynomometers are extremely expensive and cumbersome and should be avoided if possible.
SUMMARY OF THE INVENTION
The object of the present invention is to provide improved diagnostics for an internal combustion engine cooling system.
The invention is predicated in part on the discovery that the pressure upstream of the coolant system bypass with the thermostat closed can be utilized as a measure of mass flow of coolant, and therefore of coolant pump health; and in part on the discovery that the difference in such pressure at a high speed and a low speed as well as the high speed pressure allows determination of probable cause for a low reading of high speed pressure.
According to the present invention, temperature of the coolant is measured to insure that the thermostat of a coolant system of an internal combustion engine is closed, and the pressure of the coolant between the pump and the bypass measured at high and low speeds is used to diagnose the health of the cooling system.
The invention avoids the necessity for multiple pressure sensors, which are very expensive, by permitting use of but a single pressure sensor. The invention also allows testing of the pressure at a point which is highly accessible: specifically, at the thermostat inlet. The invention provides an indication of pump health and of engine coolant passage restriction by testing pressure at a single point in the cooling system.
The foregoing and other objects, features and advantages of the present invention will become more apparent in the light of the following detailed description of a preferred embodiment thereof, as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified schematic block diagram of a diagnostic system including engine parameter sensing apparatus and exemplary electronic processing apparatus, in which the present invention may be incorporated;
FIG. 2 is a simplified block diagram of engine parameter sensing apparatus for use in the embodiment of FIG. 1;
FIG. 3 is a simplified schematic diagram of tooth timer means for obtaining instantaneous, sub-cycle engine speed in the embodiment of FIG. 1;
FIG. 4 is a diagramatic illustration of principles of the invention; and
FIG. 5 is a simplified block diagram of the cooling system of an engine with probes which may be used in a diagnostic system incorporating the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a system which may incorporate the present invention is illustrated as representing the architecture of a typical data processing system or computer together with special purpose apparatus related to an engine diagnostic system of the type in which the invention may be incorporated. Specifically, the system incorporates engine sensors and signal conditioners 10 of a well known type which are adapted to be disposed for response to various parameters or discrete conditions on an engine under test, as described more fully hereinafter. Some of the sensors relate to pressures, temperatures and the like and are therefore analog signals, the magnitude of which is a measure of the parameter being sensed. The outputs of the sensors are fed over lines 13 to an analog to digital converter (A/D) 11 when selected by an A/D multiplexer 12 in response to a particular sensor address applied thereto by the program of the data processor. In addition, a tooth sensor may sense the passage of teeth on the flywheel of the engine to provide a tooth signal on a line 14, the intertooth time interval of which (when the engine is running) is measured by a tooth timer 15 and provided on tooth count lines 16. Another discrete signal is a cylinder or cycle identification signal (CID) on a line 17 which is applied to a CID centering circuit 18 to provide a CID signal on a line 19. The raw CID signal on the line 17 is a signal from a proximity sensor disposed to sense movement of an engine member once in each cycle of the engine, such as the rocker arm for the intake valve of one of the cylinders or a cam, if desired; this provides information of the cylinder-by-cylinder position of the engine at any moment in time in the same fashion as the number one firing in a spark ignition engine, and also provides cycle-to-cycle division of the engine's angular position as it is running or cranking.
In accordance with the invention, the parameters of the engine as provided through the A/D converter 11, and the instantaneous position information with respect to the engine as provided by the CID signal on the line 17 and the tooth signals on the line 14 may be used in diagnosis of the engine in accordance with the invention herein.
Additional special apparatus which may be used (although as described hereinafter is not necessarily required) includes a tooth counter and decode circuit 20, and a pair of counters 20a, 20b referred to as counter 1 and counter 2, and an interval timer 20c, and special purpose registers 22, which may be used (as an alternative to memory) to retain certain factors that are used so often as to render it advisable to have them directly available to the program rather than having to access them in memory, in order to cut down processing time and complexity of programming. Such registers may contain factors utilized in processing data (such as multiplicands used in digital filtering of the data and the like) and information relating to the particular engine under test (such as number of strokes and cylinders) which may be entered by switches manipulated by an operator, the switches feeding binary decode circuits such that the decode constantly reflects the position of the switch on a steady state basis in the manner of a register.
The remainder of FIG. 1 is illustrative of one type of data processing apparatus, which is shown for illustrative purposes herein since it is a type that may be advantageous for use where general purpose programming is not required, but rather limited functions are to be performed. A computer, as is known in the art, includes memory (or accessible storage), and arithmetic unit, program control, and the necessary gates, data flow and event decode or monitoring circuits so as to permit advancing logically through the steps which are to be performed. Specifically, a memory 24 may be loaded from a variety of inputs shown on the data flow under control of a memory multiplexer 25 which is enabled and addressed by the program so as to select which of the possible inputs to memory are to be applied thereto, if any. The memory 24 is responsive to a memory address register 26 which may respond to a counter used in program control in a usual fashion. The output of the memory is available to other portions of the data flow, such as print and display apparatus 27 and the arithmetic apparatus including arithmetic unit input registers, referred to herein as an A register 30 and a B register 31 under control of register gates 32 which are controlled by the program in a known fashion. Herein, the output of the A register and the B register is available to the register gates 32 and to the main data flow, so that their contents may be moved between the registers 30, 31 or to the memory 24. This is to facilitate the particular type of processing which may be employed in an engine diagnostic system, as is described more fully hereinafter. The registers 30, 31 feed an arithmetic unit of a known type 35, the function of which, controlled by the program, is to add, subtract, multiply or divide, to provide answers to a result register 36 as well as providing indications of the sign of the result. As indicated in FIG. 1, the result register may be available at the input to the arithmetic unit through the gates 32; alternatively, as is common in many computers the result register could be automatically one of the inputs to the arithmetic unit, and it can be loaded directly from the memory upon a proper command.
In order to provide data inputs to the memory for initialization and to permit a degree of control over the system during processing, a keyboard 38 of a usual variety may be provided. In addition to data inputs, the keyboard may have control function keys that permit choice to the operator of loading memory from the result register or of loading memory in response to the keyboard, depending upon conditions which may be displayed in the print and display apparatus 27.
For the rather limited number of tests being performed in apparatus incorporating the present invention, the program may be controlled in a variety of ways. One way is a program ROM 40 which provides input gate addresses to control the inputs to the memory, the arithmetic input registers, and the A/D converter, etc.; the memory address; the functions to be performed by the arithmetic unit, and other commands such as commands to the memory to cause it to read or write, and to start the A/D converter 11, and the like. Sequencing is controlled by unconditional branch instructions (which provide a branch address) and by skip instructions (dependent on conditions) provided to a branch/skip control 42 at the input to the program counter 44, which is also responsive to system clocks 46. Thus, as is known, for each program clock signal received from the system clocks, the program counter may be advanced, skipped once or twice, or reset to the branch address, in dependence upon the presence of branch or skip instructions.
It should be understood that the particular processing apparatus used, and the degree of use of special purpose apparatus, is dependent upon the particular implementation of the present invention which is to be made, and forms no part of the present invention. If the invention is utilized in a complex, sophisticated diagnostic system in which a variety of diagnostic functions are required, then the type of apparatus selected for processing may be more sophisticated and capable of general purpose utilization in order to accommodate the special requirements of all of the diagnostic procedures to be performed. However, the cost of programming complexity of such a processing system may be unwarranted in a diagnostic system which performs either relatively few or relatively simple tests. As is more apparent in the light of detailed operational descriptions hereinafter, well known processing systems (such as NOVA and PDP/11) employing only programs provided through techniques well known in the art, may be utilized in conjunction with the engine sensors and conditioners 10, suitable input and output apparatus (such as the keyboard 38 and the print and display apparatus 27) and, depending on the processing power of the data processing system selected, some special purpose hardware which may be found advisable, such as the tooth timer 15, the tooth counter 20 and some special registers 22. However, the well known processing systems referred to hereinbefore can provide adequate memory capacity to perform the tooth timing and counting functions, and to provide for the storage of all required parameters and engine information in the memory, as is readily apparent to those skilled in the art.
Referring now to FIG. 2, a plurality of engine sensors in a diagnostic system incorporating the present invention may include, among others not shown in FIG. 2, a starter voltage probe or clamp 46, a starter current probe 47, an atmospheric pressure transducer 48, which could be disposed in general proximity to the engine under test, a pressure transducer 49 to measure the intake manifold air pressure, a filter pressure transducer 50 to measure the pressure of the fuel downstream of the fuel inlet filter, a fuel pressure transducer 51 to measure the pressure at the fuel injector inlet rail of the engine, a coolant pressure transducer 52 which may preferably measure the pressure of coolant at the inlet to the coolant thermostat, a coolant temperature transducer 53 to measure coolant temperature, preferably at the inlet to the thermostat. In a diagnostic system incorporating the present invention there may also be a proximity sensor 54, which may comprise an RGT Model 3010-AN Magnetic Proximity Sensor, provided by Electro Corporation, Sarasota, Fla., for sensing the passage of flywheel teeth past a particular point adjacent to the flywheel housing, and a proximity sensor 55 such as a Model 4947 Proximity Switch distributed by Electro Corporation, for sensing the presence of an engine member which moves in a unique fashion once in each cycle of the engine, which is one revolution in a two stroke engine or two revolutions in a four stroke engine. The proximity sensor 55 may preferably be mounted through the valve cover adjacent to a rocker arm related to the intake valve of one of the cylinders of the engine, thereby to provide information as to the particular point of an engine cycle once in each cycle, as well as to delineate successive engine cycles as the engine is rotating.
Each of the sensors of FIG. 2 is applied to a suitable one of a plurality of signal conditioners 56, 57 to filter out unwanted noise, and to provide, through an amplifier, suitable level adjusting as is appropriate for the circuitry being fed thereby. For instance, the signal conditioners 56 scale the signals to the proper level so that each of them can be fed through a common A/D converter 12 (FIG. 1). The signal conditioners 56, 57 can be suitable ones of a wide variety known in the art, and form no part of the present invention.
Referring now to FIG. 3, the tooth timer 15 includes a counter 60 which repetitively counts clock pulses on a line 61 that may be supplied by system clocks 46 in FIG. 1. The counter is parallel-fed to a buffer 62, the output of which comprises the tooth counts. The counter is running substantially all of the time since a very high frequency clock signal can be utilized on the line 61 (anywhere from tens of KHz to tens of MHz) whereas at speeds from 300 rpm to 2,000 rpm the frequency of the tooth signals on the line 14 may be on the order of 10 Hz to 100 Hz, depending upon the number of teeth. Thus the few clock signals lost during the tooth to tooth resetting of the counter are miniscule.
Each time that a tooth signal appears on the line 14, the next clock signal will set a D-type flip flop 63, the Q output of which is applied to a D-type flip flop 64. The second clock signal following the tooth signal therefore sets the D-type flip flop 64, and since its Q output is applied to a D-type flip flop 65 the third clock signal will cause it to become set. The very first clock signal, after the appearance of the tooth signal, is decoded by an AND circuit 66 since it responds to Q of flip flop 63 and not Q of flip flop 64 and 65; this provides a load buffer signal on a line 67 to cause the buffer 62 to be loaded in parallel from the counter 60. The second clock signal following the appearance of the tooth signal will cause an AND circuit 68 to respond to the Q of flip flops 63 and 64 and the not Q of flip flop 65 so as to generate a clear counter signal on a line 69 which is applied to the clear input of the counter 60 causing it to be cleared to zero. The third clock signal, by setting the flip flop 65, simply eliminates the clear counter signal on the line 69 so that the next leading edge of the clock signal and all subsequent clock signals will be counted in the counter 60. Whenever the tooth signal disappears, (which is totally immaterial) the next three clock signals in a row will cause resetting of the flip flops 63-65, in turn, since each of their D inputs will go down. The counter and the buffer are independent of the resetting of the flip flops 63-65 since both AND circuits 66, 68 operate only during a progression with flip flop 63 on and flip flop 65 off, which does not occur during the resetting of the flip flops.
Thus the tooth timer 15 provides tooth counts on the line 16 which are stable, throughout substantially each intertooth interval. The processing apparatus of FIG. 1 may therefore sample the tooth counts at random. The tooth timer 15 thereby provides very accurate, subcyclic speed measurement, on a tooth to tooth basis, which provides speed indications many times within each individual cylinder stroke portion of each engine cycle.
In the detailed description of exemplary processing hereinafter, the term "ringgear" is sometimes used in place of "flywheel"; they mean the same thing; the abbreviation "RGT" means "ringgear teeth", a stored factor indicating the number of teeth on the flywheel of the engine under test. This may be determined and entered from engine specifications, or as set forth in a commonly owned copending application of Stick et al, Ser. No. 684,037, entitled "Determination of Number of Teeth on an Internal Combustion Engine Flywheel". Other abbreviations include: "RSLT" = result register; "MEM" = memory; "Ctr" = counter; "Factor" means a memory location or a register where the factor is available; "CMPLT" means A/D conversion is completed; "spd" means speed; and other abbreviations are apparent in the drawing. Parentheticals after "MEM", such as "(Freq)", indicate addresses, chosen at will by the programmer, or partially determined by counter two, if so indicated.
The exemplary system herein is designed for four-stroke, six-cylinder engines. If desired, the programming may be altered to compare counts (particularly counter two) with loaded indications of engine variables, such as cylinders, in a well known fashion.
Referring now to FIG. 5, an exemplary cooling system of an engine includes a coolant pump 100, an engine 102 having coolant passages 104 therein, a radiator 106, a thermostat 108 to control flow of coolant to the radiator, and a bypass 110 which bypasses the coolant back to the pump when the thermostat is closed. As indicated by a notch 112 in the bypass 110, the bypass can be considered to be a restriction or an orifice such that the pressure across it will provide an indication of the flow through it, as is known in the art. Since the pressure at the inlet to a pump such as the pump 100 is extremely low compared to the output pressure thereof, the pressure at the thermostat 108 can be considered, in accordance with the invention, to be indicative of the pressure across the restriction represented by the bypass 112. Therefore, the coolant pressure transducer 52 can be tapped in near the thermostat inlet to provide indications of cooling system health. In order to insure that the thermostat is closed, temperature may be sensed at the thermostat inlet by the coolant temperature transducer 53.
Referring to FIG. 4, several plots 114-116 of pressure as a function of speed are shown. The plot 114 shows the pressure rise with speed of a good cooling system, having a healthy pump and no undue restriction in the coolant passages of the engine. The plot 115 shows the pressure rise with speed for a cooling system in which there is no undue restriction in the engine but the pump capacity is impaired. And the plot 116 shows the rate of pressure rise with speed for a system in which the pump is healthy but there is an undue restriction in the engine passages.
If the pressure were measured at only one point, it would be impossible to determine whether a low pressure reading was caused by a bad pump or by excessive engine passage restriction. The present invention measures the pressure at low idle (P-Lo) and measures the pressure at high idle (P-Hi) and uses as an indication of cooling system health P-Hi and the difference between P-Hi and P-Lo (hereinafter referred to as the difference, D).
The tests herein are made by accelerating the engine to high idle and starting the test, and when the test is complete (or after a second or so) allowing the engine to decelerate to low idle. When at high idle, the speed is checked, and then the temperature is checked to see if it is between 140° and 160°, and then the pressure measurement is made. After decelerating, the temperature is again checked to see if it is within the aformentioned range, and the speed is checked to see if it is in a range between 600 and 900 rpm, although this range can be adjusted, and the pressure is once again read.
The speed measurements are made herein by the tooth sensor and timer, which sense the passage of teeth and record a count of the number of clock signals fed to the counter on a tooth-to-tooth basis. The number of flywheel and made or ringgear teeth (RGT) can be determined from manufacturer's specifications and provided in either a register or a predetermined location in memory prior to the test. Or, if desired, the teachings of the aforementioned Stick et al application may be utilized to determine the number of ringgear teeth on the flywheel, available in memory; none of this forms any part of the present invention. The fraction of a revolution traversed as each tooth passes the sensor is simply the ratio of one divided by the total number of teeth. The time for that fraction of a revolution to occur is simply the counts of the interval timer divided by the frequency of clock signals fed to the interval timer. Since frequency of the clock feeding the counter is expressed in Hz, and speed is normally expressed in revolutions per minute, a factor of 60 must be employed in a well known fashion. To actually determine the speed from the counts provided by the tooth counter the relationship is the ratio of one tooth to the total number of teeth, which is divided by the ratio of the counts to the frequency (the frequency in turn having to be first divided by 60 to yield a result in rpm's). When comparing the actual speed of the engine as determined by the tooth timer with predetermined speeds (such as low idle and high idle speed herein) the position of speed and counts in the relationships described hereinbefore can be reversed, and the number of counts which the tooth timer will have when the engine has a predetermined speed can be precalculated and ready to use. This is done generally by multiplying the frequency of the clock times 60, all of which is divided by the product of the total number of teeth on the flywheel and the desired starting speed in rpm. This can be accomplished in the exemplary diagnostic system of FIG. 1, assuming the specificiation speeds (low idle of about 800 rpm and high idle of about (2200 rpm) are available in memory, with the following instructions; and since only a single test need be made at high idle, and the low idle factor can be computed as the engine decelerates, the speed factor can simply be saved in the B register, and then the tooth timer can be compared therewith as follows:
1. Load MEM (Freq) TO A REG
2. load MEM (RGT) to B REG
3. divide
4. Load RSLT to A REG
5. load MEM (2200 RPM) to B REG
6. divide
7. Load RSLT to A REG
8. load 60 Factor to B REG
9. multiply
10. Load RSLT to B REG
11. load Tooth timer to A REG
12. subtract
13. Skip one if -
14. Branch to 11
Having checked to see that the engine is idling above rated speed, the system will now check to see that the temperature of the coolant is between 140° and 160°, and the following exemplary process assumes that factors are available in memory which are representative of these temperatures for comparison purposes, in a well known fashion. Exemplary instructions are:
15. Load MEM (160 Factor) to A REG
16. a/d mpx to Coolant Temp
17. Start A/D
18. skip one if CMPLT
19. branch to 18
20. Load A/D to B REG
21. subtract
22. Skip two if -
23. Display Error
24. End
25. Load MEM (140 Factor) to A REG
26. subtract
27. Skip one if +
28. Branch to 24
Having determined that the speed and temperature are proper, the system can now measure the high speed coolant pressure as follows:
29. A/D MPX to Coolant Pres
30. Start A/D
31. skip one if CMPLT
32. branch to 31
33. Load A/D to MEM (P-Hi)
34. Display "LO"
The last instruction is simply indicative of instructions which may be used to indicate to the operator that the high speed test is completed and that he can allow the engine to decelerate to low idle for the next test. However, since the electronic processing herein is so fast, there is no need of this because the operator can simply raise the engine to high idle, leave it for a second, and then allow it to return to low idle. The system will then check to see that the engine is at low idle in a manner similar to that described hereinbefore, except this time it tests against a window of speeds which are taken herein for example only as between 600 and 900 rpm, as follows:
35. Load MEM (Freq) to A REG
36. load MEM (RGT) to B REG
37. divide
38. Load RSLT to A REG
39. load MEM (900 RPM) to B REG
40. divide
41. Load RSLT to A REG
42. load 60 Factor to B REG
43. multiply
44. Load RSLT to B REG
45. load Tooth timer to A REG
46. subtract
47. Skip one if +
48. Branch to 23
And then a second test is made at a lower rpm which is taken herein to be on the order of 600 rpm as follows:
49. Load MEM (Freq) to A REG
50. load MEM (RGT) to B REG
51. divide
52. Load RSLT to A REG
53. load MEM (600 RPM) to B REG
54. divide
55. Load RSLT to A REG
56. load 60 Factor to B REG
57. multiply
58. Load RSLT to B REG
59. load Tooth timer to A REG
60. subtract; Skip one if -
61. Branch to 23
Then the temperature is again checked in the same fashion as before:
62-75. (Same as 15-28.)
And the pressure is read once more, this time at low speed, according to the following instructions:
76. A/D MPX to Coolant Pres
77. Start A/D
78. skip one if CMPLT
79. branch to 78
80. Load A/D to MEM (P-Lo)
And if desired, the pressure difference can be measured at this time as follows:
81. Load A/D to B REG
82. load MEM (P-Hi to A REG
83. subtract
84. Load RSLT to MEM (P-Lo)
Thereafter, such use as is desired can be made of the pressure and the pressure difference. For instance, either one could be compared against standards which have been emperically determined for the type of engine under test, to give an indication of passage or failure. On the other hand, the diagnostician can simply look at the two numbers and from experience analyze the condition of the pump and the coolant passages in the engine. As examples, typical results for testing an engine in the manner illustrated briefly hereinbefore with respect to FIG. 5 could include a good system P-Lo of 10 psia and a good system P-Hi of 35 psia, a bad system P-Hi of 20 psia, a bad pump P-Lo of 8 psia, and a P-Lo relating to excessive restriction of about 2 psia. Therefore, if P-Hi is on the order of 35 psia and the difference between P-Hi and P-Lo is on the order of 25 psia, a healthy system can be assumed. On the other hand, if P-Hi is around 20 psia the system is known to be faulty and depending upon the difference between P-Hi and P-Lo, if it is almost the same pressure as P-Hi, then an excessive restriction can be assumed but if it is much lower than P-Hi, a bad pump can be assumed.
It should be understood that the particular processing apparatus and the exemplary program steps therefor set out hereinbefore form no part of the present invention. The invention may be implemented in a wide variety of ways well within the skill of the art. For instance, tests of this type, if not being performed in an overall diagnostic system of the general type described with respect to FIG. 1 hereinbefore, may be more practical to implement with analog measuring apparatus. But if a high degree of resolution and sophistication is desired, then the digital techniques described herein may be preferable. Obviously, the present test alone could be performed with special purpose digital equipment which is far simpler than the overall system described hereinbefore. Similarly, although the invention has been shown and described with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, additions and omissions may be made therein and thereto without departing from the spirit and the scope of the invention. | A single pressure transducer tapped into the cooling system of an engine, downstream of the pump, is used to measure coolant pressure at high idle and coolant pressure at low idle while the water temperature is such as to assure the thermostat is closed; the pressure readings are equivalent to the pressure across an orifice or restriction formed by the coolant bypass when the thermostat is closed; the combination of high idle pressure and difference between high idle pressure and low idle pressure permit diagnosing whether the pump is faulty or whether there is unduly large restriction in the engine, which otherwise could not be known with a single pressure reading. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present utility patent application claims the advantage of provisional application No. 61/248,191 filed Oct. 2, 2009.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH OR DEVELOPMENT
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to sexual aids and particularly to a dildo sleeve harness which is attached to and worn on the foot of the user to allow for attachment of any strap-on compatible dildo to the bottom of the foot or to the back of the heel, the foot-worn dildo device comprising an elasticized foot-worn sleeve and an attached dildo harness through openings in which the dildo may be held or upon which the base of the dildo may rest and a strap and O-ring assembly used for holding the dildo in place against the dildo harness; the strap and O-ring assembly comprising an O-ring for surrounding the shaft of the dildo and straps attached to the dildo harness at the bottom of the foot and alternately the back of the heel together with straps that attach adjustably around the foot to hold the O-ring in place.
[0006] 2. Description of Related Art Including Information Disclosed under 37 CFR 1.97 and 1.98
[0007] Sexual satisfaction is an important aspect of a normal natural healthy life. While there are many hand-held devices for sexual self-satisfaction and body mounted devices for mutual sexual satisfaction, there is a lack of foot-mounted sexual satisfaction devices to permit hands-free sexual self-satisfaction and mutual satisfaction.
[0008] U.S. Pat. No. 6,899,671, issued May 31, 2005 to Fontenot, describes an intravaginal stimulation apparatus comprising a “Y” shaped tubular device with each of the three arms of the apparatus containing a flexible member. The apparatus is both extendable in width and length with each arm rotatably adjustable and affixed at two ends with adjustable cuffs for securing the apparatus to the user at the ankles. One end of the extendable arm is capable of quick adaptation to a variety of intravaginal appliances. In use, the apparatus is attached to the user's ankles via the adjustable cuffs, and is adjusted to the most comfortable position in a sitting or prone position. The user may then attach the intravaginal appliance of choice. Once insertion of the appliance is made, the user manipulates the apparatus by movement of the user's hips and buttocks in a natural rhythmic manner without the use of hands.
[0009] U.S. Pat. No. 6,540,667, issued Apr. 1, 2003 to Hickman, indicates a sexual assistance device and methods which may be used as a marital aid are disclosed which include two elongate members secured by a pivotal connection. A biasing element, such as a spring coil, is disposed at or adjacent the pivotal connection for biasing the opposite ends of the two elongate members away from each other. Respective supports are provided at the two opposite ends of the two elongate members which are engageable with the operator's legs. A sexually stimulating element, such as a vibrator or the like, is preferably removably attached to the pivotal connection. Thus, the operator may produce reciprocal longitudinal movement inwardly and outwardly, relative to the operator's body, by compressing and uncompressing the two elongate members with the legs of the operator thereby fully controlling movement of the sexually stimulating element by the legs of the operator. The biasing force is preferably relatively weak so as to permit easy closing of the operator's legs while still providing a suitable force to permit the legs to securely contact the ends of the two elongate members.
[0010] U.S. Pat. No. 6,849,041, issued Feb. 1, 2005 to Astin, is for a phallus retention harness for retaining a phallus with a base portion and an elongate body portion relative to a wearer with a pocket member for receiving and retaining the phallus wherein the pocket member has a first panel and a second panel with an inner volume between the front panel and the rear panel, an aperture in the front panel of the pocket member for enabling the elongate body portion of the phallus to extend therethrough, and an arrangement for retaining the pocket member relative to the wearer's body.
[0011] U.S. Pat. No. 4,989,592, issued Feb. 5, 1991 to Chang, puts forth a type of device to improve male sexual potency; a penis protecting pad made of flexible material; on the upper edge of the penis protecting pad are two adjusting pads, and on its lower edges are left and right adjusting belts respectively pulled through the slots on the waist band. On the lower part of the penis protecting pad is a threaded tube joint to accommodate an inside threaded tube body. One end of the tube body is jointed and adhered to a flexible glans penis to form a penis-shaped structure to be worn onto a real penis.
[0012] U.S. Pat. No. 6,547,717, issued Apr. 15, 2003 to Green et al, provides a multi-facet sexual aid device for increasing the level of sexual enjoyment between partners which includes a waist belt having a first, second and third belt portion. The first belt portion has a substantially planar portion and a first and second attachment end. The planar portion is a parabolic shaped front element which include a spring-loaded attachment mechanism within a substantially central portion of the planar portion for attaching at least one prosthetic phallic element thereto, as a quick release and quickly deployed element. A couple connector is also used to couple a plurality of different prosthetic phallic elements as either a convex or concave connection to the spring-loaded mechanism. The free ends of each second and third belt portions are fixedly secured at opposing internal first and second internal surface portions via hook and loop fasteners.
[0013] U.S. Pat. No. 5,103,810, issued Apr. 14, 1992 to Chang, claims a sexual aid which has a tubular body with a connection piece, two bands sewn or adhered to a lower end of the connection piece and a guard sewn to an upper end of the connection piece. For adjustment of the tightness of the device, a waistband adhered to the guard by adhesive tapes defines slots through which pass ends of the two bands. The tubular body has a number of peaks and valleys running along spiral lines which, with a ring element, stimulate the woman in order to make her reach orgasmic phase more quickly. The tubular body is a hollow structure with a hole at the front end to allow sperm to flow therethrough.
[0014] U.S. Patent Application #20090131744, published May 21, 2009 by Pattenden, illustrates a hip-worn sexual aid device comprising an inner region, and an outer region, wherein at least the outer region is fabricated of a molded, lofted foam material that is non-porous, wherein the outer region is configured for use with at least one of an orifice, genitalia and erogenous zone of at least one user.
[0015] U.S. Patent Application #20090229617, published Sep. 17, 2009 by Bowman, provides a primarily movement-based, biomechanically advanced interactive apparatus, that can be operated via simultaneous hand and feet action to encourage participation of all major joints/muscles of the body and which is designed to work with the body in motion. The interactive apparatus is designed as a carrier for a wide range of prosthesis of an adult nature and can provide user-controlled multi-plane movement patterns for the same.
[0016] What is needed is a foot-mounted sexual satisfaction device to permit hands-free sexual self-satisfaction and mutual satisfaction.
BRIEF SUMMARY OF THE INVENTION
[0017] An object of the present invention is to provide a foot-mounted sexual satisfaction device to permit hands-free sexual self-satisfaction and mutual satisfaction.
[0018] In brief, the present invention is a dildo harness attached to a foot-sleeve, therefore making the entire entity a foot-sleeve dildo harness. The foot-sleeve dildo harness allows the user to insert a dildo vaginally or anally in the wearer or in a sexual partnor, therefore allowing for hands-free vaginal and/or anal stimulation.
[0019] The dildo sleeve harness allows for attachment of any strap-on compatible dildo to the bottom of the foot or to the back of the heel. The foot-worn dildo device comprising an elasticized (preferably neoprene) foot-worn sleeve and an attached dildo harness through openings in which the dildo may be held or upon which the base of the dildo may rest and a strap and O-ring assembly used for holding the dildo in place against the dildo harness. The strap and O-ring assembly comprises an O-ring for surrounding the shaft of the dildo and straps attached to the dildo harness at the bottom of the foot and the back of the heel together with straps that attach adjustably around the foot to hold the O-ring in place.
[0020] The advantages of the present invention include, without limitation, that it easily allows for hands-free vaginal and anal stimulation. The device can easily slide on the wearer's foot with a dildo extending from the heel and can be used by either sitting on the back of the wearer's heel (having the dildo enter the vagina or anus), or a wearer lying on the wearer's back and bending the wearer's knee may insert the dildo vaginally. The invention can also be used simultaneously by two women sitting across from each other and sliding the dildo to the bottom of the foot-sleeve dildo harness where they can insert the dildo into each other's vaginas, while using their toes for further clitoral stimulation.
[0021] In broad embodiment, the present invention is a foot-sleeve dildo harness that mounts a dildo onto the rear or bottom of the harness allowing the wearer to stimulate a vagina or anus on the wearer or on another person.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] These and other details of my invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the invention, and in which drawings:
[0023] FIG. 1A and FIG. 1B are perspective views of the preferred embodiment of the foot sleeve dildo harness of the present invention showing one dildo attached to the heel and another dildo attached to the bottom of the foot using strap and O-ring assemblies;
[0024] FIG. 2A and FIG. 2B . are perspective views of an alternate embodiment of the foot sleeve dildo harness of the present invention showing one dildo attached to the heel and another dildo attached to the bottom of the foot each through a separate opening in the dildo harness; FIG. 3 is a perspective view of the foot sleeve of the present invention showing the toe and heel openings.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In FIGS. 1A , 1 B, 2 A, 2 B and 3 , a foot sleeve dildo harness device 8 comprising a foot sleeve 10 and attached dildo harness 12 having straps 25 and 27 and O-rings 26 forming assemblies for securing any type of body attachable dildo 16 to a heel or a bottom of the foot of a wearer, as shown in FIGS. 1A and 1B , or having openings 14 and 18 in the dildo harness for receiving a dildo 16 inserted therethrough, as shown in FIGS. 2A and 2B , for vaginal and anal stimulation of the wearer or a sexual partner.
[0026] The foot sleeve 10 is worn on a foot of a wearer encircling at least a front portion including a portion of the foot bottom and further encircling an ankle and a heel portion of the foot with a heel opening 22 and a toe opening 24 to allow ventilation and toe stimulation.
[0027] The dildo harness 12 comprises a dildo receiving strip 13 , extending down the back of the heel and along the bottom of the foot, attached to the foot sleeve 10 by stitching, adhesive, mechanical fasteners, mating hook and loop fasteners or other attaching means and may extend in one strip of dildo receiving material 13 down the back of the foot, around the heel, and along the bottom of the foot or may be in two separate components, one on the heel and the other on the bottom of the foot. The dildo harness 12 further comprises strap 25 and 27 and O-ring 26 means for attaching any of a variety of dildos 16 to the device on a bottom of the foot so that any type of body attachable dildo 16 extends orthogonally downward from the bottom of the foot and on a heel of the foot so that the dildo 16 extends orthogonally rearward from the heel of the foot for vaginal or anal insertion in the body of the wearer or the body of a sex partner.
[0028] In FIG. 1A and 1B , the means for attaching any of a variety of dildos 16 comprises as least one dildo harness 12 having a dildo receiving strip 13 for receiving a base 15 of each of the dildos 16 resting on the strip and an O-ring 26 for encircling the base 15 of each of the dildos 16 and at least one adjustable strap 25 extending from the O-ring 26 to encircle the foot of the wearer to secure the dildo 16 to the sleeve 10 . The foot encircling strap 25 has a clamp 21 for securing the strap and an adjustable buckle 23 to adjust the length of the strap. The first strap 25 encircles the front of the foot to secure the dildo 16 on the bottom of the foot and encircles the ankle and heel of the foot to secure the dildo 16 at the back of the foot. It is preferred that a pair of harness strip attaching straps 27 attach each of the O-rings 16 to the harness strip 13 preferably by a snap 28 A attached to a mating snap 28 B on the harness strip 13 and an overlapping portion of the strap which encircles the O-ring and attaches to itself adjustably by mating hook and loop fasteners 29 A and 29 B attached to facing sides of the straps 27 .
[0029] In FIG. 2A and 2B , the dildo receiving strip 13 has one opening 14 and 18 for a dildo 16 there through to receive the dildo 16 inserted through the at least one opening. The bottom opening 18 receives the bottom dildo 16 inserted therethrough with the base 15 of the dildo retained between the dildo receiving strip 13 and the sleeve 10 . The back heel opening 14 receives the back heel dildo 16 inserted therethrough with the base 15 of the dildo retained between the dildo receiving strip 13 and the sleeve 10 .
[0030] In FIG. 3 , the sleeve 10 has a top opening 20 to receive the foot of the wearer inserted therein and a heel opening 22 for ventilation and a toe opening 24 for ventilation and to allow stimulation by the toes of the wearer.
[0031] The foot sleeve 10 can come in multiple sizes (small, medium and large) to fit multiple foot sizes and can range from 4 to 5 inches deep and 4 to 5 inches in height. The dildo harness 12 may be between 3 to 3.5 inches in diameter and 4.5 to 5.5 inches in length. In FIG. 2 , the rear hole 14 may be 0.5 to 1 inch in diameter and the bottom hole 18 may be 0.5 to 1 inch in diameter. The O-rings of FIG. 1 may come in different sizes to accommodate different sizes of dildos.
[0032] The construction details of the invention are that the foot-sleeve 10 and dildo harness 12 may be made of a flexible yet supportive material such as neoprene, or any other sufficiently flexible and stretchy material. Further, the various components of foot-sleeve 10 can be made of different materials.
[0033] While it is likely that different manufacturers may produce the same type of dildos 16 with differing shapes and sizes, it is also likely that one particular manufacturer may produce a model of the same type of dildos 16 which is comprised of a similar design and dimensions that would fit through the dildo harness 12 . This dildo 16 would then be used for vaginal and/or anal stimulation.
[0034] The hook and loop fastener straps 27 are removable and are adhered by a simple snap. The female end of the plastic buckle straps 25 A and 25 B are sewn onto the foot-sleeve permanently. The male end of the plastic buckle straps may have a metal snap that allows you to remove them for attaching to different sized O-rings for dildos with different girths.
[0035] The dildo receiving strip 13 may be just another piece of neoprene sewn to the foot sleeve 10 for extra durability and comfort. This is what the dildo's base actually rests on in FIG. 1A and 1B .
[0036] In use, the wearer will slide their foot through top opening 20 of the foot-sleeve 10 . Once the foot-sleeve 10 is on their foot, the user's heel is exposed through heel opening 22 and toes are exposed through toe opening 24 , as seen in FIG. 3 , for proper support and ventilation.
[0037] The present invention easily allows for hands-free vaginal and anal stimulation. The device can easily slide on the wearer's foot with a dildo extending from the heel and can be used by either sitting on the back of the wearer's heel (having the dildo enter the vagina or anus), or a wearer lying on the wearer's back and bending the wearer's knee may insert the dildo vaginally. The invention can also be used simultaneously by two women sitting across from each other and sliding the dildo to the bottom of the foot-sleeve dildo harness where they can insert the dildo into each other's vaginas, while using their toes for further clitoral stimulation.
[0038] In broad embodiment, the present invention is a foot-sleeve dildo harness that mounts a dildo onto the rear or bottom of the harness allowing the wearer to stimulate a vagina or anus of the wearer or of another person.
[0039] It is understood that the preceding description is given merely by way of illustration and not in limitation of the invention and that various modifications may be made thereto without departing from the spirit of the invention as claimed. | A foot-sleeve dildo harness uses any of a variety of dildo devices secured in position on a bottom or heel of the foot and extending perpendicularly therefrom. The dildos provide vaginal or anal hands-free stimulation performed on a wearer or on a sexual partner. | 0 |
This is a division, of application Ser. No. 430,229, filed Jan. 2, 1974 now U.S. Pat. No. 3,893,917.
BACKGROUND OF THE INVENTION
Molten aluminum in practice generally contains entrained solids which are deleterious to the final cast metal product. These entrained solids usually derive from three sources. Some are particles of aluminum oxide which are drawn into the liquid stream from the floating oxide layer on its surface, and some entrained particles are fragments of furnace lining, transfer trough and other portions of the molten aluminum handling equipment which are eroded and entrained in the flowing aluminum stream, and some particles are precipitates of insoluble impurities such as intermetallics, borides, carbides or precipitates of other aluminum compounds, such as chlorides. When these inclusions appear in the final cast product after the molten aluminum is solidified, they cause such final product to be less ductile or to have poor finishing characteristics. Accordingly, it is desirable to remove entrained solids from the molten aluminum stream before it is cast into a solid body which may be used as such or subjected to forming operations such as rolling, forging, extrusion, etc.
Filtering processes to remove entrained solids from liquids are accomplished by passing the solid-laden liquid through a porous filter medium that will not pass the solids. Filtering molten metal in general, and molten aluminum in particular, creates special problems because the liquid is so aggressive that it is difficult to find a filter medium capable of withstanding it.
In general, two methods of filtering are used for removing entrained solids from molten aluminum alloys before casting. The most common filter medium is an open weave glass cloth screen placed in the metal transfer trough, around the spout or even in the molten metal pool in the top of the solidifying ingot. These cloth screens are able to remove only the larger sizes of inclusions from the metal and are easily ruptured during use because the glass fibers become very weak at the temperature of molten aluminum. In another prior art procedure, molten aluminum is filtered through a bed of loose alumina particles, for example, of tabular alumina, but it often suffers from the drawbacks normally associated with bed filters in that it passes too many solids, there is a strong tendency to channeling which prevents efficient use, and pore size of the filter is not easily controlled but rather readily changes under conditions of use so that, even when originally of proper dimension, it cannot be efficiently maintained. In addition, the metal must be kept constantly molten when the filter is not in use.
Accordingly, it is a principal object of the present invention to provide an improved molten metal filter and a method for preparing same and also a method for filtering molten metal therethrough.
It is an additional object of the present invention to provide a filter and method as aforesaid which is inexpensive so that it may readily be used on a throw away basis.
A further object of the present invention is to obtain a filter and method as aforesaid which obtains high filtration efficiency.
Further objects and advantages of the present invention will appear hereinafter.
SUMMARY OF THE INVENTION
In accordance with the present invention it has now been found that the foregoing objects and advantages may be readily achieved.
The present invention provides a highly efficient method of filtering molten metal, especially aluminum, through a disposable filter characterized by being a ceramic foam material having an open cell structure with a plurality of interconnected voids surrounded by a web of said ceramic. The molten metal is poured through the ceramic foam material at a rate of from 5 to 500, and preferably 30 to 100, cubic inches per square inch of filter area per minute, thereby removing entrained solids from the molten metal. The filter of the present invention is prepared by:
A. providing an open cell, hydrophilic flexible organic foam material having a plurality of interconnected voids surrounded by a web of said material;
B. impregnating said material with an aqueous ceramic slurry so that said web is coated therewith and said voids are filled therewith;
C. compressing said material to expel from 25 to 75% of said slurry therefrom while leaving said web coated therewith;
D. releasing the compression so that the web remains coated with said slurry;
E. drying said material; and
F. heating the dried material to first burn out the flexible organic foam and then sinter the ceramic coating, thereby providing a fused ceramic foam having a plurality of interconnected voids surrounded by a web of fused ceramic in the configuration of said flexible foam.
Preferably after step (D) but before step (E) the slurry coated flexible foam is formed to the configuration required for filtration and retained in said formed configuration throughout the drying step (E) and heating step (F), with the forming restraint released following step (F).
In accordance with the present invention it has been found that it is possible to prepare low cost, porous, ceramic filtration media for molten metal, especially aluminum, having densities less than 30% of theoretical and in many cases only 5 to 10% of theoretical. The filter of the present invention represents an extremely efficient and low cost filter for use in filtering molten metal. With the extremely high ratios of available area for filtration at a controlled pore size, a given projected area of the filter media is inherently much less susceptible to clogging by nonmetallic particulate. Since the filters of the present invention are extremely inexpensive to prepare, it is quite feasible to use these filters on throw away basis.
DESCRIPTION OF DRAWINGS
The present invention will be more readily understood from a consideration of the following illustrative drawings in which :
FIG. 1 is a photomicrograph at a magnification of 400X showing metal residue after filtration through the filter of the present invention and after passing the filtered metal through a pressure filter disc; and
FIG. 2 is a photomicrograph at a magnification of 400X showing metal residue after filtration through a conventional tabular alumina bed filter and after passing the filtered metal through a pressure filter disc.
The photomicrographs will be discussed in more detail in the examples.
DETAILED DESCRIPTION
In accordance with the present invention the ceramic foam is prepared from an open cell, hydrophilic flexible foam material having a plurality of interconnected voids surrounded by a web of said flexible foam material. Typical material which may be used include the polymeric foams such as polyurethane foams, and the cellulosic foams. Generally, any combustible organic plastic foam may be used which has resilience and ability to recover its original shape. The foam must burn out or volatilize at below the firing temperature of the ceramic material which is employed. Also, one should use a foam material having from 5 to 100 pores per inch in order to provide the necessary filtration surface. The dimensions of the foam material may, of course, be varied depending upon the desired dimensions of the end filter material. Generally, one utilizes a foam material having a thickness of from 1/4 to 4 inch, with from 1 to 2 inch being preferred.
The aqueous ceramic slurry which is employed depends naturally on the desired ceramic material for the chosen metal to be filtered. One must have sufficient properties in the final product to stand up to the particular molten metal with respect to chemical attack and structural and/or mechanical strength to stand up to the particular elevated temperature conditions. In addition, the slurry should have a relatively high degree of fluidity and be comprised of an aqueous suspension of the ceramic intended for use in the filter. Typical ceramic materials which may be employed include alumina, chromia, zirconia, magnesia, titanium dioxide, silica and mixtures thereof. For use with molten aluminum and its alloys, an alumina based slurry is quite satisfactory. For use with copper and its alloys, either zirconia or chromia are preferred. Normally, the slurry contains from about 10 to 40% water. Additives may be employed in the slurry such as binders.
The flexible foam material is then impregnated with the aqueous ceramic slurry so that the fiber-like webs are coated therewith and the voids are filled therewith. Normally, it is preferred to simply immerse the foam in the slurry for a short period of time sufficient to insure complete impregnation of the foam.
The impregnated foam is then compressed to expel from 25 to 75% of the slurry while leaving the fiber-like web portion coated therewith. In a continuous operation one may pass the impregnated foam through a preset roller to effect the desired expulsion of slurry from the foam and leave the desired amount impregnated therein. Naturally, this may be done manually by simply squeezing the flexible foam material to the desired extent. At this stage the foam is still flexible and may be formed into configurations suitable for specific filtration tasks, i.e., into curved plates, hollow cylinders, etc. It is necessary to hold the formed foam in position by conventional means until the organic substrate is decomposed, or preferably until the ceramic is sintered. The impregnated foam is then dried by either air drying or accelerated drying at a temperature of from 100° to 700° C for from 15 minutes to 6 hours. Air drying may be achieved in from 8 to 24 hours. After drying, the material is heated at an elevated temperature to sinter the ceramic coating on the fiber-like webs. It is preferred to heat the dried impregnated material in two stages, with the first stage being to slowly heat to a temperature of from 350° to 700° and hold within this temperature range for from 15 minutes to 6 hours in order to burn off or volatilize the web of flexible foam. Clearly this step can be part of the drying cycle, if desired. The second stage is to heat to a temperature of from 1200° to 1600° C and hold within said temperature range for from 15 minutes to 10 hours in order to sinter the ceramic. It is also preferred to control the heat up rates for each of these stages in order to avoid collapse of the ceramic material. Thus, the heat up rate from stage one is preferably less than 10° C per minute and the heat up rate in stage two is preferably less than 100° C per minute.
The resultant product is a fused ceramic foam having an open cell structure characterized by a plurality of interconnected voids surrounded by a web of said ceramic, with the ceramic foam material having a density of less than 30% of the theoretical density for a ceramic material of the same size. Naturally, the ceramic foam may have any desired configuration based on the configuration needed for the particular molten metal filtration process. Although, naturally, these configurations can be many and varied, semielliptical configuration is preferred for filtration in a transfer trough between the furnace and the casting mold in filtering molten aluminum. A hollow cylindrical configuration is preferred for filtering molten aluminum passing through a down spout. In either case, the height of the filtration media must exceed that of the molten metal to be filtered. It is a particular advantage of the filtration process of the present invention that excessive heads of molten metal are not required in order to start the filtration process utilizing the filter of the present invention.
In accordance with the present invention, the specific features thereof will be more readily understandable from a consideration of the following illustrative examples.
EXAMPLE I
A polyurethane foam material was provided having a thickness of 1/2 inch and containing 10 pores per inch. A ceramic slurry in water was provided containing 85% alumina, 15% chromia and 25% water. The foam material was immersed in the slurry and kneaded to remove air and fill the voids with the slurry and also to coat the fibrous webs of the foam with said slurry. The foam thus impregnated was removed from the slurry and subjected to compression to squeeze approximately 50% of the slurry out of the foam by passing the impregnated foam through preset rollers. The foam material sprung back to its original dimension after passing through the preset rollers and had the fibrous urethane filaments coated with a substantially uniform residue of the ceramic slurry.
Two samples were dried in the following manner. Sample A was air dried for 24 hours and Sample B was oven dried at 125° C for one hour.
Both dried samples were heated slowly at a heat up rate of 0.5° C per minute to 500° C to boil off the water and then to allow the polyurethane fibers to volatilize and/or burn out without collapsing the ceramic and without destroying the filamentary ceramic configuration. The foam was held at 500° C for 1 hour and was subsequently heated to 1350° C at a rate of 1° C per minute, held at 1350° C for 5 hours to permit the ceramic to sinter together and thereby provide an open cell ceramic foam material having a configuration of the original polyurethane foam material
EXAMPLE II
Several ceramic foam materials were prepared in a mannner after the procedure of Example I having the following configurations: 6 inches wide; 10 inches long and 1 inch thick. These materials were cemented into transfer troughs between the furnace and the casting mold for testing as a filter material for molten aluminum. Approximately 5,400 pounds of aluminum alloy 5252, containing from 2.2 - 2.8% magnesium, up to 0.08% silicon, up to 0.10% copper, and up to 0.10% manganese, were transferred through the filter at an average rate of about 80 cubic inches per square inch of filter per minute. It was surprising that a large head was not required to start the metal flow. Conventional rigid filtration media normally require a head of approximately 1 to 2 feet; whereas, a head of 2 1/2inches was required to start the metal flow in the process of the present invention.
The filtration effect was excellent. FIG. 1 shows a cross-section of a pressure filter disc through which had been run aluminum alloy 5252 after filtration through the filter of Example I as shown in this Example II. FIG. 2 shows a similar filter disc through which had been passed the same volume of alloy 5252 which had previously been filtered through a commercial tabular alumina bed filter. The higher the residue in the filter disc shown in FIG. 1 and FIG. 2, the lower is the efficiency of the previous filter. It will be clearly seen that there is more residue in FIG. 2 than in FIG. 1, thereby indicating that the commercial tabular alumina bed filter is less efficient than the filter of the present invention.
The pressure filter test is means of concentrating and examining the nonmetallic particulate in a 20-25 lb. sample of molten aluminum. To this end, molten metal is ladled carefully into a preheated 25 lb. clay graphite crucible into the base of which is set a 30 mm diameter, 3 mm thick porous silica disc plug. 90% of the metal is then forced through the disc by application of air pressure and the remaining metal solidified in situ. The disc and adjacent metal are then sectioned, polished, and examined by normal metallographic techniques to reveal the quantity of nonmetallics filtered out.
EXAMPLE III
A ceramic foam filter of the present invention was prepared in a manner after Example I having the configuration 3 1/2 inches wide, 6 inches long and 1 inch thick. This filter was cemented into a transfer trough between the melting furnace and the casting mold. Some 1800 lbs. of copper alloy 194, containing from 2.1 - 2.6% iron, from 0.05 - 0.20% zinc, from 0.01 - 0.04% phosphorus and balance essentially copper, were transferred through the filter at an average rate of 35 cubic inches per square inch of filter per minute. A head of 0.75 inch was all that was required to start metal flow through the filter of the present invention. Filtration was excellent and resulted in a 10% improvement in elongation of the cast metal over that of unfiltered metal. Tensile strength was not affected.
This invention may be embodied in other forms or carried out in other ways without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes which come within the meaning and range of equivalency are intended to be embraced therein. | The present invention resides in an improved molten metal filter and a method of preparing same and a method of filtering molten metal therethrough. The filter is an open cell ceramic foam material having a plurality of interconnected voids surrounded by a web of said ceramic. | 2 |
RELATED APPLICATION
[0001] This non-provisional patent application claims the benefit of pending U.S. provisional patent application Ser. No. 60/658,332, filed Mar. 3, 2005, entitled “No-Smear Flyswatter,” the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates in general to fly swatters, and more particularly to flyswatters of the type that reduce the likelihood of leaving insect residue when struck.
BACKGROUND OF THE INVENTION
[0003] Flyswatters have been used for many, many years. Many attempts have been made to overcome various problems with flyswatters and the use thereof, as evidenced by the many patents directed to such subject matter. For example, the following patents illustrate the various advancements made in the field of flyswatters: U.S. Pat. No. 1,299,580 by Krumlaw; U.S. Pat. No. 1,412,312 by Little; U.S. Pat. No. 1,650,548 by Sullivan; U.S. Pat. No. 1,860,939 by Miller and U.S. Pat. No. 3,673,730 by Hegenberger.
[0004] The most common application of a typical flyswatter is to swat an insect and smash it between the flat striking surface of the flyswatter and an object on which the insect rests. A sufficient force is applied to crush or severely harm the insect, resulting in its subsequent death. In this process the delicate body of the insect is usually smeared or broken apart—leaving a mess or residue on both flyswatter and the object supporting the insect.
[0005] Often, when a flyswatter is used, it will not be swung with the full force available to the person using the flyswatter, because they know that doing so will smear the insect all over the object. Thus, a person using a flyswatter will typically try to swing fast enough to catch the insect, but slow at the very end of the actual strike so as not to smear the residue of the insect over the object. The problem with this is that it makes it more difficult to catch fast-moving insects.
[0006] The present invention eliminates this problem because the user does not need to be concerned with slowing down the motion of the flyswatter, or trying to hit the insect at an angle so as to not smear it. With the present invention, the user can swing the flyswatter as fast and as hard as they want, and attempt to land the flyswatter flat against the insect resting surface, and be comfortable with the assurance that the insect will not be smeared all over the object. Performing the operation in this way also maximizes the chances of actually striking the insect.
[0007] It can be seen that a need exists for a flyswatter involving a relatively minor modification to conventional flyswatter designs, thereby eliminating or greatly reducing the mess associated with a standard insect swatting operation.
SUMMARY OF THE INVENTION
[0008] According to a feature of one embodiment of the invention, disclosed is a flyswatter having an array, collection, or pattern of relatively small protuberances, or raised features distributed on at least one striking surface of the flyswatter. The purpose or effect of the spaced-apart protrusions is to leave a gap during the swatting operation between the striking surface of the flyswatter and the object on which the insect rests.
[0009] According to an advantage of the invention, the relatively small gap between the object and the striking surface of the flyswatter is to limit the amount of mechanical compression imposed on the insect. Because the amount of mechanical compression imposed on the insect is reduced, the insect is less likely to break apart or smear on either the flyswatter or the object. The primary goal to kill the insect while still leaving the body of the insect generally intact and/or mostly whole, is thus achieved.
[0010] The extent of the gap between the elastically deflected swatting member and the object is determined as a function of the height of the protrusions, where the protrusions are positioned on or in relation to the otherwise-flat striking surface, the elasticity of the material from which the swatting member is constructed, and the velocity of the swatting member at the moment of impact. If the flyswatter is intended for use with larger insects, then a larger gap can be provided by making the flyswatter with taller protrusions on (or related to) the striking surface. Each side of the striking surface can have protrusions of a different height. On one striking surface of the flyswatter the protrusions can be made to accommodate larger insects, and on the other striking surface the protrusions can be made to accommodate smaller insects.
[0011] According to one embodiment of the invention, disclosed is a flyswatter having a handle, and attached thereto is an elastically deformable swatting member having at least one striking surface for striking an insect. The swatting surface has a plurality of spaced-apart protrusions attached thereto, and a spacing of said protrusions are sufficient so that when the swatting member is struck against a surface on which the insect rests, portions of the elastically deformable swatting member located between adjacent protrusions deform sufficiently so that one deformed portion contacts the insect. The elastically deformable swatting member and the protrusions are constructed so that a substantial portion of each deformed portion does not contact the surface during the swatting operation.
[0012] According to another embodiment, disclosed is a flyswatter having a plastic handle, and attached to the handle is a plastic swatting member with a swatting surface on each side thereof. The swatting surfaces are adapted for striking an insect. Each said swatting surface has a plurality of spaced-apart plastic bumps projecting above the respective swatting surfaces, and portions of the swatting member located between neighbor bumps are constructed so as be deformed toward a surface when the swatting member is struck against the surface. The deformation is convex shaped so that a crown portion of the deformed portion approaches the surface being struck. However, a substantial portion of the deformed portion does not contact the struck surface, and each deformed portion of the striking member returns to a rest state immediately subsequent to the deformation. The handle, the swatting member and the bumps are all molded as an integral flyswatter.
[0013] According to the invention, disclosed also is a method of swatting insects with a flyswatter. The method includes the steps of applying a force to the flyswatter to strike a surface on which the insect rests. The striking force of said flyswatter on the surface causes a plurality of small contact areas of said flyswatter to contact the surface, and causes the large swatting areas located between said small contact areas to elastically deform and bow toward the surface and strike the insect. Only a small area, if any, of the bowed large swatting areas contacts the surface being struck. The deformation of at least one large swatting area of the flyswatter imparts a quick and sharp impact to the insect without substantially compressing the insect on the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Further features and advantages will become apparent from the following and more particular description of the preferred and other embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters generally refer to the same parts, functions or elements throughout the views, and in which:
[0015] FIG. 1 is an isometric view of the top side of the flyswatter according to the invention;
[0016] FIG. 2 is a side view of a bottom side of the flyswatter of FIG. 1 ;
[0017] FIG. 3 is a bottom view of the flyswatter of FIGS. 1 and 2 ;
[0018] FIG. 4 is a cross-sectional view of a portion of a striking member as it deforms during a striking operation;
[0019] FIG. 5 is another embodiment employing a screen-type striking member with bumps embedded therein;
[0020] FIG. 6 is another embodiment of the invention employing a combination of curved ridges and bumps;
[0021] FIG. 7 is yet another embodiment employing linear ridges and bumps;
[0022] FIG. 8 is an isometric view of a bump having a pillar shape;
[0023] FIG. 9 is an isometric view of a bump having somewhat of a hemispherical shape with a blunt end; and
[0024] FIG. 10 is an isometric view of a bump with a truncated cone shape.
DETAILED DESCRIPTION OF THE INVENTION
[0025] A typical flyswatter is constructed with a striking member that is approximately square, measuring about 4 to 4.5 inches on each side. The striking member is usually a thin flat piece of perforated plastic or rubber that is square or rectangular. The striking member includes opposing striking surfaces, each for striking an insect, or the like. The perforations function to allow air to quickly escape through the striking member, rather than from under the striking member. The striking member tends to “roll” on the object upon which the insect rests, and conforms to the shape of the object. A conventional flyswatter is constructed with a simple wire or plastic handle molded into or integral with the striking member. The wire or plastic handle is typically 16 to 18 inches long.
[0026] The flyswatter of the present invention can embody the basic design of the conventional flyswatter, with one or more modifications. The flyswatter according to the invention is constructed to provide “no-smear” characteristics. This characteristic is achieved in one form by providing an array of small convex protrusions, in the form of bumps in one embodiment, on one or both of the otherwise flat striking surfaces of the flyswatter. Other protrusions could include small ridges or ribs of various shapes and sizes that are raised above the striking surface. Because the striking surface includes protrusions, the air can quickly escape therefrom, without requiring of apertures in the striking member.
[0027] The preferred embodiment of the invention is illustrated in FIGS. 1-3 . The flyswatter 10 is molded with a suitable material, and includes a substantially square striking member 12 molded integral with a handle 14 . The striking member 12 is about 3/32 inch thick, and is preferably constructed of an elastically deformable material. Other striking member thicknesses could be employed to achieve an elastically deformable striking member 12 . The striking member 12 can be constructed with plastic materials currently employed in making flyswatters, in addition to unbreakable, flexible plastics, such as polyethylene, polypropylene and vinyl. Perforations formed through the striking member 12 can be utilized to enhance the flexibility thereof. The perforations are formed, if at all, at locations in the swatting member, other than centered between the protrusions. Preferably, although not a necessity, the striking member 12 of the preferred embodiment is perforated. The opposing surfaces or faces of the striking member 12 can be considered striking surfaces. One striking surface 16 is shown in FIG. 1 , and the opposing striking surface 18 is shown in FIGS. 2 and 3 .
[0028] According to the preferred embodiment, a plurality of protrusions is distributed over the striking surfaces 16 and 18 . The protrusions occupy about ten percent, or less, of the area of the striking surfaces 16 and 18 . One set of protrusions is illustrated as reference numeral 20 on striking surface 16 , and is considered a “bump.” Another set of protrusions 22 are shown formed on the opposite striking surface 18 . The height of each bump 20 formed on the striking surface 16 may be about 1/16 of an inch. The height of each bump 22 formed on the opposite striking surface 18 may be about ⅛ of an inch. Alternatively the bumps on both sides of the striking member 12 can be formed with the same height. The different bump heights allow the flyswatter 10 to be effective with different sizes of insects. In a preferred embodiment, and with the swatting member 12 constructed of a typical plastic vinyl with which flyswatters are presently made, there would preferably be between 15 and 25 bumps uniformly distributed on each swatting surface 16 and 18 .
[0029] The particular shape of the bumps 20 and 22 is not critical to the effectiveness of the invention. The bumps 20 and 22 can thus be formed with many shapes. One shape easy to implement would be a generally hemispherical shape. With this implementation, the protrusions on the striking surface of the flyswatter would indeed look like small bumps. Other shapes could be cones, pyramids, squares, rods, etc, as more fully described below. The bumps can be arranged on the striking surface in a grid pattern of rows and columns, with a spacing therebetween of one-inch, or more. Many other patterns or grid shapes of bumps on the striking member 12 can be utilized.
[0030] FIG. 4 illustrates the principles and concepts of the flyswatter 10 of the invention during a striking or swatting operation. A portion of the flyswatter 10 is illustrated as it appears just after contact has been made between the bumps 22 of the flyswatter 10 and the object 24 on which the insect rests. During a swatting operation, the flyswatter 10 is grasped by the handle 14 and swatted so that the swatting member 12 lands on a surface of the object 24 on which an insect 26 sets. As the swatting member 12 becomes adjacent to the object 24 , the bumps 22 make contact with the object 24 . The swatting member 12 itself may flex until it is entirely parallel with the object 24 at the end of the swatting operation. It is at this time that portions of the flyswatter 10 of the invention continue to flex to strike the insect 26 without smashing it. The kinetic energy of the swatting member 12 , and especially each portion 28 that bridges or spans the bumps 22 , causes such portions 28 to elastically deform and bow downwardly, as shown in FIG. 4 . As used herein, elastic deformation includes its commonly accepted definition of a change in shape of a body that is reversible when the stress is removed. The downwardly deformed portions 28 of the swatting member 12 have the effect of striking the insect 26 with a sudden impact and immobilizing the insect 26 without smashing it onto the object 24 . In many instances, the insect 26 will be killed or immobilized by being stunned without smashing it. It is possible, albeit a low probability, that the insect 26 will be struck by one of the bumps 22 , in which event it will be smashed on the surface 24 . It is believed that the portions 28 of the striking member 12 that elastically deform downwardly during the swatting operation do so with a snap action, based on the elasticity of the material with which the striking member 12 is constructed. In other words, the downwardly deflected portions 28 react very quickly to the stopping of the swatting member 12 on the object 24 , thus imparting a substantial energy in a very short period of time to the insect 26 caught thereunder.
[0031] It can be seen from the foregoing that the bumps 22 maintain the crown portions of the elastically deformed portions of the swatting member 12 elevated above the surface of the object 24 , and prevent direct contact with the object. It can also be seen that there is a relationship between the spacing of the bumps 22 , the height of the bumps 22 and the elasticity of the striking member 12 . The spacing of the bumps 22 can be reduced if the elasticity of the striking member 12 is increased. In like manner, the height of the bumps 22 can be made greater if the elasticity, and/or the tendency to change the shape of the striking member 12 is increased.
[0032] FIG. 5 illustrates another embodiment of the invention. Here, the flyswatter 30 is constructed with the striking member 32 made of a fine-mesh wire netting. Small plastic parts 34 a and 34 b , such as bump half parts, can be made in such a manner that they are insertable through the wire mesh of a typical wire-constructed flyswatter, and captured in the medial position within the wire mesh of the striking member 32 . This would result in one half of the plastic part 34 a protruding from one side of the wire mesh striking member 32 , and the other half of the plastic part 34 b protruding from the other side of the wire mesh striking member 32 . Such an arrangement would allow for the same gap effect that is achieved with the striking member 12 that has the bumps 20 and 22 molded onto its surface. These small plastic parts 34 a and 34 b can also be molded as two separate pieces that snap together and capture the fine mesh wire netting of the striking member 32 therebetween.
[0033] FIG. 6 illustrates yet another embodiment of the flyswatter according to the invention. The flyswatter 40 includes a circular rib 42 formed generally in the center of the striking member 44 . The rib 42 need not be circular, but could be oval or some other geometric shape. In addition, the rib 42 need not be continuous, as shown, but could have breaks in it. Shown spaced around the circular rib 42 are other bumps, one shown as numeral 46 .
[0034] FIG. 7 depicts a flyswatter 50 constructed according to another embodiment of the invention. The striking member 52 has formed thereon one or more linear ribs 54 , and spaced around the ribs 54 are one or more bumps 56 . The location and number of ribs 54 and bumps 56 can be varied in a manner different from that shown. In addition, different combinations of curved ribs, linear ribs and bumps can be employed on a swatting member to achieve the desired effect described above.
[0035] FIG. 8 illustrates a bump 60 formed with a pillar shape. The bump 60 is either formed integral with the swatting member 62 , or attached thereto by suitable means. The pillar-shaped bump 60 has a flat end to thereby reduce marring or otherwise causing delicate surfaces from being dented when struck by the bumps 60 of the flyswatter during a swatting operation. The edges of the bumps could be rounded to remove any sharp corners. The bumps 60 are preferably constructed with a size and of a relatively hard material so as not to deform substantially during the swatting operation. This allows the swatting member 62 to undergo an elastic deformation and bow outwardly without being cushioned by the bumps. Similarly, it is preferable that the bumps formed on the top and bottom sides of the swatting member 12 be aligned with each other. This alignment of the bumps allows the area of the swatting member 12 between the bumps to be elastically deformed Without being affected by the weight of a bump above the deflected portion of the swatting member 12 . A bump located on a top surface of the swatting member 12 without a bump also located just below the top bump, would be undesirable, as a lone top bump would function as a weight on the deflecting portion of the swatting member and would slow down the response, but increase the extent by which the swatting member is elastically deformed.
[0036] FIG. 9 illustrates another type of bump 64 which can be employed with the invention. The bump 64 is generally hemispherical shaped with a blunt or flat top 66 . The blunt top 66 reduces marring of delicate surfaces, in the manner noted above in connection with the bump 60 of FIG. 8 . The bump 64 can be molded to or fastened to the swatting member 68 .
[0037] FIG. 10 illustrates another bump 70 that is cone-shaped, but with a truncated top 72 . The bump 70 can be mounted to or formed integral with the swatting member 74 .
[0038] While various shapes of bumps are described above, the invention is not limited to such shapes. Those skilled in the art may find that other bump shapes, including ridge shapes, can be utilized without departing from the concepts of the invention.
[0039] The advantages of the invention can be appreciated by understanding that a typical insect 26 , with its fragile body, can be immobilized or mortally wounded, without smearing, by the application of a relatively small impact force from a flyswatter 10 . The insect 26 does not need to be fully compressed between the object and the striking surface 18 of a flyswatter 10 . While this certainly will result in the death of the insect 26 , it also causes an unnecessary mess. The mess often resulting from swatting an insect can be reduced by the use of a much smaller force, quickly applied, which still results in the destruction of the insect. When protrusions are present on the striking member of a flyswatter, at the moment of impact of the flyswatter on an object, portions of the swatting member around the protrusions will elastically deflect toward the object. However, there may still be a small gap between the object and the deflected portions of the striking member of the flyswatter. The gap indicates that the deflection of the swatting member has not been stopped by contact with the object being struck by the protrusions. The existence of the gap enhances the impact force imparted to the insect. Instead of being squeezed to near zero thickness (smeared or smooshed), the insect is only squeezed or compressed to a thickness approximately equal to either the height of the protrusions, or the spacing of the gap.
[0040] At the instant that a typical flyswatter operation is completed, the elastic material of the striking member momentarily flexes and deflects due to the high force of impact. This results in a relatively large radius of deflection, or bowing outwardly, of that portion of the striking member spanning the protrusions. At the moment of impact between the protrusions and the object, the elastic deformation of portions of the swatting member will bow outwardly in a snap action toward the object. After being fully deformed outwardly, the deflected portions of the swatting member will snap back, similar to the action of a rubber band snapping, thus imparting impact energy to any insect which happens to be struck by the deflecting portion of the swatting member. Such action can damage the insect's wings or other parts of its body, or kill the insect. The effect of this is that the insect is stunned, otherwise immobilized, or killed without any mess at all, or at least a reduced degree of messiness.
[0041] From the foregoing, disclosed is a flyswatter constructed to reduce the smearing of an insect when squeezed against an object surface. The flyswatter of the invention includes a swatting member with spaced-apart protrusions on a surface thereof for contacting the object on which the insect rests. Portions of the swatting member located between the protrusions are adapted for elastic deformation when the protrusions strike the object. The elastic deflection of the numerous parts of the swatting member is effective to quickly strike the insect without smearing it on the object. The snap action of the deflecting swatting member imparts sufficient energy to the insect to destroy it without completely compressing the insect onto the object.
[0042] While the preferred and other embodiments of the invention have been disclosed with reference to flyswatters, it is to be understood that many changes in detail may be made as a matter of engineering choices without departing from the spirit and scope of the invention, as defined by the appended claims. In addition, not all of the features and advantages of the invention need be employed to realize the individual aspects thereof. Accordingly, those skilled in the art may find that various of the aspects of the invention may form a combination that provides advantages in particular situations. | A flyswatter ( 10 ) having an elastically deformable swatting member ( 16 ) with a plurality of protrusions ( 20 ) formed thereon. The protrusions ( 20 ) are spaced apart on the swatting member ( 16 ), and have a height somewhat less than the height of the insect. When the swatting member ( 16 ) is struck on an object upon which the insect rests, the protrusions ( 20 ) contact the object, and the swatting member ( 16 ) elastically deforms and bows outwardly and strikes the insect without flattening or squishing the insect. | 0 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to the field of nautical safety devices. More particularly, the present invention relates to a device for providing emergency transit between a marine vessel and the surrounding water. More particularly yet, the present invention involves a modular, foldable ladder, where the ladder is portable and stowable aboard the vessel and deployable over a side of the vessel to provide safe transit between the water and the deck of the vessel.
2. Description of Prior Art
Throughout the long history of marine vessels, there have been the inherent hazards of water. For numerous reasons, it has been and continues to be necessary to provide some means by which an individual may both safely enter the water from a deck of a vessel and safely access the deck of the vessel from the water. Accordingly, various designs of ladder structures are found throughout the art of nautical devices. Many such designs are permanently mounted along the periphery of the vessel, typically supported by some portion of the vessel's hull. These types of ladder structures may be pivotally or statically mounted. Alternatively, many such ladder structures are removably mountable along the vessel's periphery. It is within this removably mountable category of ladder structure that the present invention resides.
In the field of nautical safety devices, there have been attempts, with varying degrees of success, to facilitate transit between the deck of a vessel and the water surrounding the vessel by providing a removably mounted ladder structure. In general, the complexity of such efforts has undercut whatever advantages they might otherwise offer during both emergency and non-emergency situations. Indeed, during typical nautical emergencies the time and effort involved in deploying and using complex and inefficient ladders is self-defeating. Typical non-folding ladders that are not welded, or otherwise fixed, to the vessel are usually cumbersome, heavy, and not readily stowable. Deployment of such prior-art ladders is difficult at best for one person working alone and valuable time is lost during emergency situations when a cumbersome or complex ladder is deployed. Some prior-art ladders even pose a hazard themselves when deployed because they are shaped and/or mounted in such a way that causes its elements to catch, foul, or snare lines or pier structures. Other prior-art nautical ladder structures have their own disadvantages.
One related prior-art nautical ladder is that of Lang (U.S. Pat. No. 3,892,290), which has two-piece and three-piece foldable configurations. In both configurations, there is included a set of parallel rails that have end-hooks latchable onto corresponding mounts along a side of a boat. Deployment of the Lang ladder involves holding it in a precarious position near the side of the boat so that it can be attached to the mounts. This deployment technique makes the risk of losing the ladder into the water high. As well, Lang fails to provide any rails or guides to assist anyone using the ladder. While a guide-chain is provided in one configuration, this is far from an ideal grasping element for assistance. Typically, chains pinch fingers and thus present the danger of a user losing his grip while on the ladder. Accordingly, Lang fails to provide a safe nautical ladder.
Other nautical ladders exist that are deficient for the same reasons noted in regard to the Lang device. A general defect of prior-art nautical ladders is that they are not suitable for emergency situations where medium to large vessels are concerned. Indeed, prior-art nautical ladders of the removably mounted type are typically designed for use in small recreational boats. Mounting such nautical ladders on a large vessel--such as a ferry--where the deck is much farther from the water becomes difficult to impossible. This is because the requisite length of ladder typically precludes stowability aboard boats. Even telescoping or otherwise extendable designs found in the prior-art do not provide adequate or safe transit between a deck and the water. Due to wave swells and the fixed height of the sides of the boat, the distance between the deck and the water can range from four up to eight feet or more. Concurrent with the development of the prior-art nautical ladders described above, other ladders have been developed with the goal of quickly facilitating transit between water and a boat. Four representative prior-art devices are those of Ritten (U.S. Pat. No. 4,724,925), Baranowski (U.S. Pat. No. 4,538,314), Sell (U.S. Pat. No. 3,794,140), and Thornburg et al. (U.S. Pat. No. 3,195,680).
The Ritten device is a nautical ladder having a ladder section and a mount section. The mount section has a step unit and a mount unit. The step unit is a pair of tubular siderails that carry flat tread steps. The mount unit is a pair of spaced-apart, tubular sections rotatably connected to the step unit. Mounting members, into which such tubular sections fit, permit the ladder to be mounted on a topside surface of a boat while supporting the ladder in its operating orientation. Ritten exhibits several flaws, including, most importantly, a lack of any guides or railings to assist a user. Further, aside from the small tread steps, Ritten does not provide any platform near water-level that would be a suitable landing for exhausted or injured individuals, as would be needed during emergency rescue situations. Yet further, the rigid ladder section of Ritten is neither compact for better stowability nor extendable for use on a large boat such as a ferry. Accordingly, Ritten fails to provide a nautical ladder that is both suitably safe and quick to set up during emergency situations on a large boat.
Baranowski includes a nautical boarding ramp similar to Ritten but having adjustable features that make it foldable. While the ramp of Baranowski also provides a landing platform, it does not provide sufficient extendibility to the water surface such as is needed for use on large boats with decks high above the water. Also, no safety rails or guides are shown for use with the ramp. Indeed, due to its cumbersome design, the ramp itself may be easily dropped overboard when a user attempts to hook it to the side of the boat. Therefore, Baranowski is not suitable for emergencies on large boats where safety and speedy setup are required.
Sell includes a boat ladder similar to the prior-art mentioned above but one that has guide rails. While a landing platform is shown as a component of the Sell device, it is located at boat-deck level and only one step is provided therebelow for access to and from the water. Although this design is suitable for recreational use on a small boat, it fails to provide a suitable transit between the water and a large boat. As well, Sell suffers from the deficiency seen throughout the prior-art, the absence of deployment means that is safe for both the rescuer and the rescued with minimal risk of dropping the ladder overboard.
Similar to the device of Sell, the boarding platform of Thornburg at al. includes a boat ladder for a small watercraft having a platform landing at deck-level and a foldable step therebeneath. Thornburg et al. does not, however, provide any guides or rails. Again, although this design is suitable for recreational use on a small boat, it fails to provide suitable transit between the water and a large boat during emergencies. Thornburg at al. suffers from the deficiency pervasive throughout the prior-art: the absence of quick, easy, and safe deployment with reduced risk of losing the ladder overboard.
Accordingly, the prior art fails to provide any nautical ladders suitable for quick and safe assembly and use--especially in emergency situations. Therefore, what is needed is a nautical ladder that is truly suitable for emergency use. What is also needed is such a device that is lightweight, portable, and of sturdy design. Further, what is needed is such a device that enables fast and safe utilization with a large boat, such as a ferry. Still further, what is needed is such a device that is readily deployable by a sole deckhand with minimal risk of dropping or otherwise losing the device overboard. What is also needed is that the nautical ladder system be mounted in such a way so as to eliminate any protrudances that can catch, foul, or snare lines or pier structures. Also, what is needed is such a nautical ladder system that is both foldable and compact so as to provide easy stowing.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a marine vessel overboard emergency system that includes a lightweight, portable, and sturdy ladder suitable for quick and safe assembly by a sole deckhand in emergency situations. While the instant invention is primarily directed to emergency situations such as that of an individual falling overboard from a marine vessel into the surrounding water, it may also be utilized for a variety of non-emergency purposes including, but not limited to, water access during recreational boating, snorkeling, scuba-diving, water-skiing, swimming, and passage between two vessels. Another object of the present invention is to provide such a ladder that is readily deployable for use on a large boat--e.g., a ferry--with minimal risk of dropping, or otherwise losing, the device overboard. Yet another object of the present invention is to provide such a nautical device that is mounted in such a way so as to eliminate any elements that might otherwise catch, foul, or snare lines or pier structures. Still another object of the present invention is to provide such a nautical ladder system that is foldable and compact so that it is easily stowable.
The marine vessel overboard emergency system of the present invention includes a three-section folding ladder with guide rails, a mounting frame, and a slightly modified deck area on the vessel where the system is to be made available. Although, this discussion focuses on use of the present invention during emergency situations such as when a passenger falls off a ferry into water, any similar situation requiring passage between the deck and the water is applicable. Also, for purposes of illustration, the present invention is discussed in terms of being machined from aluminum; however, it should be understood that the instant invention is not intended to be limited to machined aluminum. Rather, any suitable method of fabrication and material may be used that is sufficiently dependable, sturdy, and lightweight.
In general, the marine vessel overboard emergency system of the present invention is designed to unobtrusively stow in whatever place other emergency nautical devices aboard a boat are located or anywhere else that is out of the way, but nevertheless readily accessible. This is accomplished by the introduction of a collapsibly folding feature. While stowed or transported, the system is compact. The system has a three-sectioned ladder portion that includes an upper ladder having rungs, a middle platform, and a lower ladder having rungs. All three sections are hinged together and have nesting widths so that the lower ladder may be folded into the middle platform and, in turn, both of these may be folded into the upper ladder. The system also has a mounting frame separable from the ladder portion that connects the ladder portion to a modified deck area of a marine vessel.
The upper ladder has two parallel side rails that include fixed elongated hand-grips. A lateral guide is movably mounted on each hand-grip so that the lateral guide may slide along the hand-grip and pivot on one end vertically and horizontally. This movement of the lateral guides both enhances stowability via increased foldability and allows vertical slack in situations where wave swells cause someone grasping the lateral guides to be dipped into and out of the water. The other end of the lateral guide is connectable to orifices located on the lower ladder. The two parallel side rails of the upper ladder are formed by three layered segments that provide an elongated slot therein. The mounting frame has two rollers that are connectable to the elongated slot of the upper ladder. The mounting frame also has two footings that are securable in foot-receiving slots. According to the instant system, the foot-receiving slots are placed in the deck. These foot-receiving slots have openings that are flush with the deck surface. (This is the only modification made to the deck area.) As the particular deck surface will include a portion of a doorway, there will usually be a raised threshold area. The mounting frame is shaped such that it is recieved flush within the threshold. Although two footings and two related foot-receiving slots are discussed herein, any number of such footing/slot pairs may be utilized so as to suitably secure the mounting frame and ladder portion to the boat deck.
For deployment, a deckhand will first remove the folded ladder portion hitherto secured to an interior wall of the vessel by the mounting frame. The mounting frame is carried to the modified deck area and placed flush within the threshold. The deckhand will then carry the ladder portion to the modified deck area and set the ladder portion adjacent to the mounting frame. Alternatively, the ladder portion may be slidably moved along the deck, via its rounded edges, to its placement adjacent to the mounting frame. Optional safety straps may be employed at this point between the vessel and either or both the ladder portion and mounting frame. The ladder portion is next unfolded to its open and locked position, seated on the rollers, and then rolled along the rollers for deployment alongside the boat. Because the rollers securely grasp the inside of the elongated slot when the ladder portion is on the deck, there is no opportunity for the ladder portion to be dangled from the deck and no possibility that it will be lost overboard during proper deployment.
It is to be understood that other objects and advantages of the present invention will be made apparent by the following description of the drawings according to the present invention. While a preferred embodiment is disclosed, this is not intended to be limiting. Rather, the general principles set forth herein are considered to be merely illustrative of the scope of the present invention and it is to be further understood that numerous changes may be made without straying from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a marine vessel overboard emergency system in accordance with the preferred embodiment of the present invention positioned on a cut-away portion of a ferry deck.
FIG. 2 is a top view of the mounting frame portion of the invention as shown in FIG. 1.
FIGS. 2a, 2b, 2c, and 2d are close-up views of one of the rolling elements of the mounting frame portion as shown in FIG. 2 and disassembled.
FIG. 3 is a side view of one of the two rail sections of the upper ladder section of the invention as shown in FIG. 1.
FIG. 3a is a side view of the first layer of one of the rail sections of the top ladder section as shown in FIG. 3.
FIG. 3b is a side view of the second layer of one of the rail sections of the top ladder section as shown in FIG. 3.
FIG. 4 is a schematic view of the upper ladder, middle platform, and lower ladder as shown in FIG. 1 representing the nesting characteristics of the present invention.
FIG. 5 is a side view of the lower railing of the present invention as shown in as shown in FIG. 1.
FIG. 5a is a side view of the end element that is connectable to the lower rail element of FIG. 5 as shown attached in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a marine vessel overboard emergency system 10 is shown according to the preferred embodiment of the present invention. The system 10 includes an upper ladder 12 that has two hand-grips 15, 15' and two rails 30, 30'. The upper ladder 12 is pivotally connected at its lower end to a middle platform 13 which, in turn, is pivotally connected to a lower ladder 14. While these connections are pivotable, stop-elements 13c (one hidden) make certain that upper ladder 12 and middle platform 13 are angled at 90 degrees to one another. Hook-elements 14c (one hidden), likewise, make certain that the lower ladder 14 and the middle platform 13 are angled at 90 degrees to one another. Lower ladder 14 includes two pairs sleeves 14a and 14b and is connected to the middle platform 13 such that the lower ladder 14 is set off from a vessel 18. Each of two lateral guides 16, 16' is movably connected between a respective hand-grip 15, 15' and the lower ladder 14. For clarity, only the right side of the system 10 will be referenced hereinafter with respect to FIG. 1; however, it should be understood that the system 10 is symmetrically constructed.
Also as shown in FIG. 1, the sleeve 14a secures the lateral guide 16 in position on the lower ladder 14. However, the lateral guide 16 is both vertically and horizontally pivotable via a hinge 16a and slidable along hand-grip 15 via slider 15a when not secured in sleeve 14a. A mounting platform 11 is connected to the upper ladder 12 via a pair of rollers 25 and 26 (shown in FIG. 2) and, in turn, the mounting platform 11 is secured in a modified deck section 17 of the vessel 18. Cross bar 24 of the mounting platform 11 is shaped so that the cross bar 24 may be received within a typical threshold (not shown). The cross bar 24 lying flush within the threshold further prevents sliding movement of the mounting frame 11. Optional platform-safety-straps 11a, 11b and ladder-safety-straps 12a, 312b are also shown attached to the system 10. These optional straps 11a, 11b and 12a, 12b secure the system 10 to a suitable part of the vessel 18 such as inside rails (not shown) in order to prevent any chance that the system 10 is lost overboard.
FIG. 2 is a top view of the mounting platform 11 detached from the system 10 of FIG. 1. The mounting platform 11 consists primarily of sides 21, 22 and cross-bars 23, 24 all held together via welding or any suitably strong method of connection. Cross-bar 23 is preferably shaped as a rod, while cross-bar 24 is preferably shaped as a plate. Reinforcements 23a and 23b add strength to the mounting platform 11. Footings 19a and 19b are provided perpendicularly affixed to sides 21 and 22, respectively. The footings 19a and 19b are preferably cylindrical and include lateral reinforcements 21a and 22a attached, respectively, between sides 21 and 22 and insides of footings 19a and 19b. Rings 21b and 22b are shown placed through each reinforcement 21a and 22a, respectively. Rings 21b and 22b provide a connection point on the mounting platform 11 for the optional frame-safety-straps 11a, 11b, as shown in FIG. 1, which are secured to the vessel 18 at some suitable location such as an inside railing (not shown). Because the mounting platform 11 is minimized in its number of parts and hence complexity, its extent and (more importantly) its weight are kept to a minimum. Rollers 25 and 26 are identical and are affixed at ends of sides 21 and 22, respectively.
In FIG. 2a, roller 25 is shown in close-up detail. Roller 25 includes a bearing 25b, a bushing 27 and a nut 28 held upon a bolt 25a that passes through side 21. The bolt 25a is formed with a slotted head 25c. The bolt 25a includes dimensions that allow the bearing 25b to be press-fit to the bolt 25a. FIGS. 2b, 2c, and 2d respectively, are detailed views of the bolt 25a, bushing 27 and slotted head 25c as shown in FIGS. 2 and 2a.
FIG. 3 is an enlarged side view of the rail 30 of one of the two sides of the upper ladder 12 as shown in FIG. 1. The rail 30 has a first section 31 (shown in FIG. 3a) upon which a second section 32 (shown in FIG. 3b) is placed. Hand-guide 15 is attached to the first section 31. While the first section 31 and the second section 32 are preferably welded together, any suitable method of strong connection may be used. With reference to FIGS. 3, 3a, and 3b, the first section 31 includes a rear side 31a and a front side 31b and a base plate 31c. Rear side 31a and front side 31b are constructed to be perpendicular to the base plate 31c. A top-plate 31d is attached to one end of the first section 31 and welded to the edges of base plate 31c as well as to rear side 31a and front side 31b. The top-plate 31d also serves to accept the combined load of the upper ladder 12, middle platform 13, and lower ladder 14 together with any individuals using the system 10. The hand-grip 15 is welded to the top plate 31d and the side 31b. The second section 32 is welded or otherwise attached to the first section 31 at the edges of rear side 31a and front side 31b to form an elongated box-like configuration that includes an elongated slot 33 and a slot opening 30a. A sliding fitting 15a is mounted on hand-grip 15 and will be discussed with reference to FIGS. 5 and 5a.
FIG. 4 is a schematic representation that shows the general relationship among the upper ladder 12, the middle platform 13, and the lower ladder 14 shown in FIG. 1. FIG. 4 is oriented from the perspective of standing on-deck looking down. FIG. 4 illustrates the relative dimensions that allow the system 10 shown in FIG. 1 to be nestingly folded so that the lower ladder 14 folds into the middle platform 13, which, in turn, folds into the upper ladder 12. In FIG. 4, this nesting arrangement is seen where the middle platform 13 has an inner width 43a that is just greater than an outer width 44a of the lower element. Similarly, the middle platform 13 has an outer width 43b that is just less than an inner width 42a of the upper ladder 12. Therefore, lower ladder 14 may be nested entirely within the middle platform 13 and both may be nested entirely within the upper ladder 12.
FIGS. 5 and 5a detail one lateral guide 16 and its respective hinge 16a (shown enlarged in FIG. 5a for clarity) as shown in operation in FIG. 1. The lateral guide 16 has a pivot-connection-end 50 that receives the hinge 16a. The hinge 16a includes an attachment side 50a and a pivot-point 50b. As seen in FIG. 1, the hinge 16a is connected to the sliding fitting 15a at the pivot-point 50b. The hinge 16a is located at the pivot-connection end 50. The hinge 16a and lateral guide 16 are preferably connected together by welding at the pivot-connection end 50; however, any suitable method of connection may be used--e.g., removable retaining clips--that allow removal of the lateral guides 16 altogether from the system 10. In operation, this hinging and pivoting arrangement provides foldability for stowing purposes.
Prior to deployment when the system 10 is stowed, the folded ladder portion (12, 13, and 14) is secured to an interior wall or other suitable location aboard the vessel 18 by the mounting frame 11. Deploying the system 10 requires first removing the mounting frame 11, optionally securing frame-safety-straps 11a, 11b between the mounting frame 11 and the vessel 18, and placing the mounting frame 11 into position in the modified deck area 17 so that the cross bar 24 of the mounting frame 11 sits flush within the vessel threshold (if applicable). The folded ladder portion (12, 13, and 14) is then carried, or slidably moved along the deck surface, to the modified deck area 17. Sliding is facilitated by the rounded edges (shown as 13a and 13b in FIG. 1). The folded ladder portion (12, 13, and 14) is then positioned inboard of the mounting platform 11 and, optionally, secured to the vessel 18 via ladder-safety-straps 12a, 12b. The ladder portion (12, 13, and 14) is then unfolded to its open position and seated on the rollers 25 and 26 so that the rollers 25 and 26 enter each slot opening 33. The opened ladder portion (12, 13, and 14) is then rolled along the rollers 25 and 26 though each elongated slot 33 and securely maintained at the closed end of the elongated slot 33 for deployment alongside the vessel 18. Because the rollers 25 and 26 securely grasp the inside of the elongated slot 33 when the ladder portion (12, 13, and 14) is yet on the deck 17, there is little opportunity for the ladder portion (12, 13, and 14) to be dangled from the deck 17 or be lost overboard. Further, use of the optional frame-safety-safety-straps 11a, 11b and ladder-safety-straps 12a, 12b substantially eliminates any possibility of losing the system 10 overboard.
It should be understood that, while the preferred embodiment mentioned here is intended to illustrate the present invention, minor changes will become apparent to those skilled in the art. Accordingly, numerous variations in design and use of the present invention may be contemplated in view of the following claims without straying from the intended scope and field of the invention herein disclosed. | A marine vessel ladder system that is primarily used for overboard emergency situations. The ladder system is collapsible and separable into two pieces with one piece substantially smaller than the other. The smaller piece serves both as a retainer to hold the larger piece in a folded, stowed position and also as a connector to fasten the larger piece to a customized area along an edge of the vessel's deck. The ladder system is deployable by one deckhand and includes vertically oriented upper and lower ladder sections with a horizontally oriented grate section therebetween. Fixed vertical railings and collapsible side railings are provided for assistance in ascending and descending the ladder system. Optional safety straps are provided to secure the system prior to and during use. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/037,620, filed on Mar. 18, 2008, and entitled “End-to-End Lamp Assembly,” which is commonly assigned with the present application and incorporated herein by reference for all purposes.
TECHNICAL FIELD
[0002] The present disclosure relates generally to purification systems and methods, and more particularly to an end-to-end lamp assembly and method of manufacturing the same.
BACKGROUND
[0003] Since almost all forms of life need water to survive, the improvement of water quality in decontamination systems has typically been a subject of significant interest. As a result, treatment systems and techniques for removing contaminants from contaminated fluids have been developed and refined over time. Prior approaches have included water treatment by applying various microorganisms, enzymes and nutrients for the microorganisms in water. Other approaches involve placing chemicals in the contaminated fluids, such as chlorine, in an effort to decontaminate supplies. Some such systems have proved to be somewhat successful; however, sever deficiencies in each approach may still be prominent.
[0004] Some more advanced treatment systems and techniques include treatments using a photolytic or a photocatalytic process. Common photocatalytic treatment methods typically make use of a technique by which a photocatalyst is bonded to contaminants in order to destroy such biomaterials. Specifically, photocatalytic reactions are caused by irradiating, such as by ultraviolet light, on the fixed photocatalyst so as to activate it. Resulting photocatalytic reactions bring about destruction of contaminants, such as volatile organic contaminants or other biologically harmful compounds that are in close proximity to the activated photocatalyst.
[0005] This irradiation may be provided by a lamp assembly in which a tubular lamp, protected by a transparent sleeve, is inserted in a cell of a photocatalytic reactor to irradiate contaminated fluid passing through that cell. Such a lamp assembly and photocatalytic reactor may be seen in U.S. Pat. No. 5,554,300 and U.S. Published Patent Application No. 2005/0211641, both of which are commonly assigned with the present disclosure and incorporated herein by reference in their entirety for all purposes. Unfortunately, even the advanced lamp assembly designs used with such system can prove to be bulky and complex in wiring, adding to both the size of the photocatalytic equipment, as well as to the overall cost of manufacturing such a system. Accordingly, what is need is a advantageous lamp assembly design that may be used with such photocatalytic equipment, that improves the efficiency in both operation and manufacturing of the overall system.
SUMMARY
[0006] Systems and methods constructed and operated in accordance with the principles disclosed herein provide a novel design for fitting two or more tube-shaped lamps end-to-end. Such an end-to-end structure may be constructed for use inside a single protective sleeve, such as one constructed of transparent quartz in embodiments where the assembly is used in a decontamination reactor equipment. In exemplary embodiments, the lamps are securely coupled, or otherwise fastened or linked, together end-to-end using any appropriate means for ensuring the integrity and longevity of the connection between the ends of the lamps. The integrity of this end-to-end connection would prevail under any and all circumstances, such as shipping or otherwise moving the assembly, or under normal or abnormal operating conditions, or even in the event that any equipment in which the lamp assembly is used fails during its operation.
[0007] In one aspect, a multiple lamp assembly is provided. In one embodiment, the lamp assembly comprises a first lamp and a second lamp, as well as a first connector on a near end of the first lamp having first and second power terminals for electrical connection to separate first and second power lines, and having a neutral terminal for electrical connection to a ground line. In addition, the assembly may comprise a second connector on a far end of the first lamp and having a second power terminal for electrical connection only to the second power line, and having a neutral terminal for electrical connection to the ground line. In some embodiments, the assembly may also contain a jumper wire electrically bypassing the second power line around the first lamp from the first connector to the second connector. Still further, the assembly may include a third connector on a near end of the second lamp having a second power terminal for electrical connection to the second power terminal of the second connector, and having a neutral terminal for electrical connection to the neutral terminal of the second connector, wherein the third connector physically couples to the second connector to couple the first and second lamps end-to-end. Also in such embodiments, a protective sleeve hermetically sealing the first and second lamps and the connectors may be provided.
[0008] In another aspect, a lighting system is provided. In one embodiment, the lighting system comprises an electrical ballast providing separate first and second power lines and a ground line. In addition, the system may include a housing with an electrical receptacle providing the first and second power lines and the ground line, as well as a tubular lamp assembly having a mount on one end for suspending the assembly from the one end. In certain embodiments, the lamp assembly may comprise tubular first and second lamps, as well as a first connector on a near end of the first lamp having first and second power terminals for electrical connection to the first and second power lines, and having a neutral terminal for electrical connection to the ground line. The lamp assembly may also include a second connector on a far end of the first lamp and having a second power terminal for electrical connection only to the second power line, and having a neutral terminal for electrical connection to the ground line. A jumper wire electrically bypassing the second power line around the first lamp from the first connector to the second connector may also be provided, wherein the jumper wire is disposed on an external surface of the first lamp. Also, the lamp assembly may provide a third connector on a near end of the second lamp having a second power terminal for electrical connection to the second power terminal of the second connector, and having a neutral terminal for electrical connection to the neutral terminal of the second connector, wherein the third connector physically couples to the second connector to couple the first and second lamps end-to-end. The lamp assembly may also include a protective sleeve connected to the mount and hermetically sealing the first and second lamps and the connectors. Finally, the lighting system may include an electrical coupling configured to electrically connect the mount to the electrical receiver on the housing.
[0009] In yet another aspect, a method of manufacturing a lamp assembly is provided. In one embodiment, the method comprises electrically connecting first and second power terminals of a first connector on a near end of a first lamp to separate first and second power lines, and electrically connecting a neutral terminal of the first connector to a ground line. The method may also include electrically connecting a second power terminal of a second connector on a far end of the first lamp to only the second power line, and electrically connecting a neutral terminal of the second connector to the ground line. Still further, such a method may include electrically bypassing the second power line around the first lamp from the first connector to the second connector. Also, the method may provide for electrically connecting a second power terminal of a third connector on a near end of the second lamp to the second power terminal of the second connector, and electrically connecting a neutral terminal of the third connector to the neutral terminal of the second connector. Additionally, in such embodiments, the method may also comprise physically coupling the third connector to the second connector to couple the first and second lamps end-to-end. Then, such a method could include connecting a protective sleeve to a mount configured to suspend the assembly from one end to hermetically seal the first and second lamps and the connectors, the mount providing the first and second power lines and the ground line to the first connector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments are illustrated herein by way of example in the accompanying figures, in which like reference numbers indicate similar parts, and in which:
[0011] FIG. 1 illustrates one embodiment of an end-to-end lamp assembly constructed according to the principles disclosed herein;
[0012] FIG. 2 illustrates an isometric view of an embodiment of the end-to-end lamp assembly disclosed herein similar to the assembly shown in FIG. 1 ;
[0013] FIG. 2A illustrates a close-up view of the joint between the inside and outside lamps created by the second and third connectors;
[0014] FIG. 3A illustrates a detailed view of the near end of the embodiment of an end-to-end lamp assembly shown in FIGS. 2 and 2A ;
[0015] FIG. 3B illustrates a detailed view of the middle section of the embodiment of an end-to-end lamp assembly shown in FIGS. 2 and 2A ;
[0016] FIG. 3A illustrates a detailed view of the far end of the embodiment of an end-to-end lamp assembly shown in FIGS. 2 and 2A ; and
[0017] FIG. 4 illustrates isometric views of the near and far ends of the inside lamp depicted in the assembly of FIGS. 2 and 2A .
DETAILED DESCRIPTION
[0018] The present disclosure provides a novel design for fitting two lamps end-to-end. Such an end-to-end structure may be constructed for use inside a single protective sleeve and held from only one end, such as for use in reactors found in decontamination equipment. Looking initially at FIG. 1 , illustrated is one embodiment of an end-to-end lamp assembly 100 constructed according to the principles disclosed herein. The disclosed end-to-end lamp assembly 100 includes two lamps 105 , 105 in a single assembly to be powered from only one end of the end-to-end lamps 105 , 110 by a single electrical ballast 115 . In exemplary embodiments, these lamps 105 , 110 may be ultraviolet (UV) lamps, but other types of lamps 105 , 110 may also be employed.
[0019] In an advantageous embodiment, the near end of the inside lamp 105 , which is the lamp 105 closest to the ballast 115 , would first be plugged into the ballast 115 in a normal manner. For example, this near end may have a four-terminal connector 120 , and the ballast 115 has a receiving connector, such a Gaynor connector (not illustrated). The far end of the inside lamp 105 could also include a four-terminal connector 125 . The outside lamp 110 , which is the lamp 110 furthest from the ballast 115 , may also include a four-terminal connector 130 on its near end. Of course, for either or both lamps 105 , 110 , different types or numbers of connectors or terminals may also be employed, so long as the power relay around the inside lamp 105 as discussed below is provided. Accordingly, although the terminals on the connectors are illustrated as pins or pin receivers, other shapes and types of terminals and connectors may be employed without departing from the spirit and scope of the present disclosure.
[0020] The four-terminal connectors 120 , 125 , 130 illustrated in FIG. 1 may be provided as two power or “line” terminals (denoted L 1 and L 2 in FIG. 1 ) and two neutral terminals (denoted N in FIG. 1 ). In addition, the neutral terminals N in each connector 120 , 125 , 130 may be electrically connected together, while the line terminals in the second and third connectors 125 , 130 may be likewise electrically connected. However, the line terminals in the first connector 120 are electrically isolated, with one line terminal L 1 electrically connected to a first power line P 1 from the ballast 115 , and the other line terminal L 2 electrically connected to a second power line P 2 from the ballast 115 . The neutral terminals on the first connector 120 are thus electrically connected to a ground line from the ballast 115 .
[0021] Continuing with FIG. 1 , the first power line L 1 and the neutral line N are electrically connected to two electrical connections 135 of the inside lamp 105 . These two connections 135 power a filament on the near end of the inside lamp 105 and are jumpered around the outside casing of this lamp 105 to a filament at its far end in order to provide the power to cause the inside lamp 105 to illuminate. The electrical connections 140 and filaments for the outside lamp 110 are similarly wired. Thus, each of the lamps 105 , 110 may include electrical connections 135 , 140 jumpered on the outside of their casings, however, it should be noted that such an electrical layout is not required. In other embodiments, the lamps 105 , 110 may be provided with different means for providing electricity to both ends of the lamps 105 , 110 .
[0022] In accordance with the disclosed principles, the outside lamp 110 is electrically connected to the inside lamp 105 to receive its power, rather than being directly connected to the ballast 115 . More specifically, as discussed above, the second power line P 2 from the ballast 115 is connected to the second power terminal L 2 in the first connector 120 at the near end of the inside lamp 105 . The second power line P 2 may then be jumpered around the inside lamp 105 via an electrical jumper wire 145 to one of the two power terminals L 1 , L 2 of the second connector 125 located at the far end of the inside lamp 105 . In addition, the ground connection is also provided to the neutral terminals N of the second connector 125 . By providing the second power line P 2 and a ground connection N to the second connector 125 fixed on the far end of the inside lamp 105 , the near end of the outside lamp 110 can then receive its power directly from the second connector 125 .
[0023] To seal and protect the lamps 105 , 110 and all of the electrical connections in the assembly 100 , a protective sleeve 145 , such as a transparent sleeve, may be provided for the assembly 100 . In embodiments employing a transparent sleeve 145 , the end-to-end lamp assembly 100 is ideal for use in the reactors found in some types of decontamination/purification equipment. For example, a photocatalytic reactor like the ones found in U.S. patent and pending U.S. patent application cited above, would benefit from a lamp assembly 100 constructed as disclosed herein.
[0024] Turning to FIG. 2 , illustrated is an isometric view of an embodiment of the end-to-end lamp assembly 200 disclosed herein similar to the assembly 100 shown in FIG. 1 . The assembly 200 in FIG. 1 also includes inside and outside lamps 205 , 210 , which are again protected within a sleeve 245 . In addition, this embodiment of the assembly 200 includes the inside and outside lamps 205 , 210 interconnected using first, second and third electrical connectors 220 , 205 , 230 .
[0025] As before, the first connector 220 is located at the near end of the inside lamp 205 , the second connector 225 is located at the far end of the inside lamp 205 , and the third connector 230 is located at the near of the outside lamp 210 . FIG. 2A provides a close-up view of the joint between the inside and outside lamps 205 , 210 created by the second and third connectors 225 , 230 . As illustrated, the second connector 225 , located on the far end of the inside lamp 205 , may comprise four female terminals 255 , while the third connector 230 , located on the near end of the outside lamp 210 , may include four male terminals 260 configured to be plugged into the four female terminals 255 on the second connector 225 .
[0026] As with the assembly 100 in FIG. 1 , the four-terminal connectors 225 , 230 illustrated in FIG. 2A may be provided as two power or “line” terminals (denoted L 1 and L 2 in FIG. 1 ) and two neutral terminals (denoted N in FIG. 1 ). As described above, the line terminals in the second connector 225 provide electricity from second power line P 2 of the ballast 115 , which is distinct from the first power line P 1 provided to operate the inside lamp 205 . The electricity from the second power line P 2 is then provided to the outside lamp 210 via one or both of the male line terminals in the third connector 230 . Also, the neutral terminals on the second connector 225 are electrically connected to the ground line from the inside lamp 205 , and that electrical ground is also provided to the outside lamp 210 via male neutral terminals on the third connector 230 when the outside lamp 210 is plugged into the inside lamp 205 .
[0027] As a result of the disclosed electrical interconnection of the inside and outside lamps 205 , 210 , the tubular lamps 205 , 210 are physically connected to each other in series, or end-to-end, while these same lamps 205 , 210 are each separately electrically connected using the jumper wire ( 145 in FIG. 1 ) to bypass the inside lamp 205 . In advantageous embodiments, the ballast 115 may provide only a single output power, but this type of interconnection allows multiple lamps to be powered by that single output power in parallel. By being electrically connected in parallel, each lamp 205 , 210 would thus operate with the same voltage while still being physically connected in “series” to one another. As a result, the disclosed assembly may take advantage of an in-line physical layout for multiple lamps, while maintaining the advantages of a parallel electrical configuration. Additionally, in embodiments where more than two lamps 205 , 210 are employed, the second power line P 2 is provided to lamp 210 via only one of the line terminals in the second and third connectors 225 , 230 , while a third power line (not illustrated) may be provided around both of the illustrated lamps 205 , 210 to a third lamp (not illustrated).
[0028] Among the other advantages a lamp assembly constructed according to the disclosed principles provides is that this unique design allows two or more lamps to be encased in a single protective sleeve, without additional wires or seals or process connections, thus reducing manufacturing costs. By connecting two or more lamps end-to-end, 50% less (or greater with more lamps in series) of the total number of protective sleeves, lamp plugs, seal, wiring harnesses, etc. are needed tubes thus, increasing the packing density of the equipment employing the lamp assembly. Also, by increasing the packing density, the overall footprint of the equipment may be reduced. Furthermore, the disclosed principles may reduce the complexity of the overall assembly, as well as the time required for assembly since there are less connections and quality control inspections to be performed. A reduction in the amount of time required for maintenance activities may also be realized. In sum, all of these advantages may come together to help improve the overall cost of the equipment by employing an assembly as disclosed herein that improves the efficiency in both operation and manufacturing of the overall system.
[0029] FIGS. 3A-3C illustrate multiple detailed views of the near end, middle, and far end of the embodiment of an end-to-end lamp assembly 200 shown in FIGS. 2 and 2A . As discussed above, this assembly 200 employs inside and outside lamps 205 , 210 physically connected end-to-end in series, while each is powered by distinct power lines. To seal and protect the lamps 205 , 210 and all of the electrical connections in the assembly 200 , the protective sleeve 245 is provided over the components of the assembly 200 .
[0030] In this embodiment, the two lamps 210 , 220 are coupled together with male electrical terminals in the third connector 230 plugging in to female terminals in the second conductor 225 (see FIG. 2B ). The coupling of these two connectors 225 , 230 provides the electrical connection from the ballast 115 to the outside lamp 210 . Specifically, the jumper wire 245 is provided from the second power line P 2 of the ballast 115 to a line terminal in the second connector 225 at the far end of the inside lamp 205 . That line terminal is then electrically coupled to a line terminal of the third connector 230 , and thus the electricity from the second power line P 2 bypasses the inside lamp 205 and provided to the outside lamp 210 . As shown in FIG. 3C , the lamps 205 , 210 may also include external wires 240 provided down the outside casing of the lamps 205 , 210 to provide electricity at both ends of the lamps 205 , 210 . As mentioned above, however, different wiring for each illuminating lamp 205 , 210 individually may also be provided instead of external return wires 240 .
[0031] In addition, looking at FIG. 3A in combination with FIG. 4 , which illustrates views of the near and far ends of the inside lamp 205 , the first connector unit 220 may also include four male terminals 265 (see FIG. 4 ) extending from the near end of the inside lamp 205 . These terminals 265 on the near end of the inside lamp 205 may be configured to plug into receiving terminals electrically connected to the ballast 115 . These receiving terminals may be provided in a standard Gaynor connector 270 , but of course any type of connecter configured to receive the terminals 265 of the first connector 225 may be employed. The Gaynor connector 270 may then be coupled to a mount 275 configured to receive and secure the protective sleeve 250 in place. This mount 275 could be constructed to house the ballast 115 inside, or could include an electrical connector 280 of its own that is electrically coupled to the ballast 115 . In addition to the benefits of the disclosed assembly 200 discussed above, such a construction allows the lamps 210 , 220 to be powered from only one end, which then further allows the entire assembly to be held from only one end. Accordingly, an assembly 200 constructed according to the principles of the present disclosure is capable of being inserted into other fixtures for use in various types of machinery, when being attached and powered for only the exposed end.
[0032] While various embodiments in accordance with the disclosed principles have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages.
[0033] Additionally, the section headings herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Brief Summary” to be considered as a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings herein. | Disclosed herein are systems and methods for a lamp assembly having a novel design for fitting two or more tube-shaped lamps end-to-end. Such an end-to-end structure may be constructed for use inside a single protective sleeve, such as one constructed of transparent quartz in embodiments where the assembly is used in a decontamination reactor equipment. In exemplary embodiments, the lamps are securely coupled, or otherwise fastened or linked, together end-to-end using any appropriate means for ensuring the integrity and longevity of the connection between the ends of the lamps. The integrity of this end-to-end connection would prevail under any and all circumstances, such as shipping or otherwise moving the assembly, or under normal or abnormal operating conditions, or even in the event that any equipment in which the lamp assembly is used fails during its operation. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a device for deterring birds from roosting or nesting on building ledges or the like.
Overpopulation of birds causes stress, diseases, and crowded breeding places that are potentially dangerous to humans and domestic animals. Bird droppings create an unsightly, unhygienic mess that can damage buildings. People have been affected by pigeon-related parasitosis caused by pigeon ticks and red blood mites. A consequence of overpopulation is that birds are constantly looking for new places to roost and nest.
It is well known to use wires to discourage birds from roosting on buildings. For example, U.S. Pat. No. 5,092,088 describes a mechanism whereby wires are attached to structures mounted on a ledge. At one end of the mechanism, the wires are attached to a retracting mechanism that adjusts the length and tension of the wires.
UK published Patent Application no. 2,237,826 describes a removable bird deterring mechanism. More particularly, a support device for a wire consists of a cover that push-fits over metal support pins hammered into a building ledge. The cover along with the wire, can be separated from the pins to allow removal of the cover and wire from the building. The cover and wire have to be stored when removed from the pins. There is the possibility of the wire getting tangled or knotted during storage. Additionally, the support pins are permanently mounted on the top surface of the building from which they protrude.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a bird deterring device which can be easily converted from an active mode in which it extends above a building surface to an inactive mode in which it is largely hidden from view.
According to one aspect, the present invention provides a wire holding mechanism for use in deterring birds from landing, roosting or nesting on a surface of a building structure, the wire holding mechanism comprising a mounting member to be attached to the building structure and an arm having spaced means for securing wire, the arm being pivotally connected at a pivot to the mounting member and being selectively pivotable to an operational protracted position in which the arm extends above the surface of the building structure and being selectively pivotable to a non-operational retracted position in which the arm lies below the surface of the building structure.
According to another aspect, the present invention provides a retractable device for deterring birds from landing, roosting or nesting on a surface of a building structure, the device comprising at least two holding mechanisms each comprising a mounting member to be attached to the building structure and an arm having spaced means for securing wire between the wire holding mechanisms, the arms being pivotally connected at respective pivots to the mounting members and being selectively pivotable to an operational protracted position in which the arms and wire lie above the surface of the building structure and to a non-operational retracted position in which the arms and wire lie below the surface of the building structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of one embodiment of a bird deterring device according to the invention;
FIG. 2 is a side view of the bird deterring device of FIG. 1;
FIG. 3 is a perspective view of the bird deterring device shown mounted in position on a building ledge;
FIG. 4 is a side view of a portion of the bird deterring device illustrating a top mounting on a ledge;
FIG. 5 is a side view similar to FIG. 4 but illustrating a bottom mounting on a ledge; and
FIG. 6 is a perspective view of a single arm bird deterring device shown mounted in position on a building ledge.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, the bird deterring device comprises, in the illustrated embodiment, two or more wire holding mechanisms 10 between which lengths of wire 11 are strung. The wire holding mechanisms 10, only one of which is illustrated in FIGS. 1 and 2, are adapted to be secured to a building ledge.
Each wire holding mechanism 10 comprises an arm 12 pivotally connected, as will be described in detail below, to a base plate 13. The arm has three small through holes 15 provided at spaced locations along the arm with the top one being located close to the free end 16 of the arm. The holes 15 receive there through the wire 11 which is secured to the arm 12 by the pinching action of respective plugs 17 received through the holes 15. The plugs offer a simple means of adjusting wire tension that has been altered through expansion or contraction.
At the lower end each arm 12 is provided with a large through hole (hidden from view in FIGS. 1 and 2) designed for receipt of screw bolt 18.
The base plate 13 is formed of a generally rectangular flat plate portion 19, through which extend two spaced holes 20, and a protrusion 21 which is integrally connected to an upper edge portion 22 of the plate portion 19 at a location displaced from the center of the upper edge portion. The protrusion 21 is located entirely on one side of the plane in which the plate portion 19 lies and includes a surface 23 which meets one flat surface 24 of the plate portion at a right angle.
The protrusion also is provided with a large through hole (hidden from view in FIGS. 1 and 2) designed for receipt of the screw bolt 18.
The screw bolt 18 is received through the hole in the protrusion 21 and then through the large hole in the arm 12 with the head 25 of the screw bolt 18 butting the protrusion 21. A washer 26, lock washer 27 and wing nut 28 are then received in turn on the screw bolt. With the wing nut 28 loose the arm 12 may be pivoted to a position relative to the base plate 13 and with the wing nut tightened the arm 12 is maintained in the selected pivoted position.
Referring to FIG. 3, illustrated is a perspective view of the bird deterring device according to the invention when installed on the upstanding back surface of a balcony wall, i.e. the surface shown is that facing away from the balcony. Shown is the "up" position in full lines and the "down" position in phantom, the "down" position being positioned substantially 180° with respect to the "up" position. The arrows show the direction of movement of the arms 12 about their pivots when retracting the device from the "up" position to the "down" position. The device when in the "down" position is obscured from the view of someone on the balcony. Bolts 29 are received through the holes 20 (hidden from view in FIG. 3) in the rectangular flat portions 19 of the base plates 13 and are secured into the upstanding surface of a balcony wall, the bolts 29 holding the bird deterring device in place. A wire 11 is shown threaded through holes in the arms 12 and the wire is secured to each arm as described for FIGS. 1 and 2 above. It will be appreciated that the bird deterring device is of a small cross sectional area and hence will be "invisible" to the naked eye at a distance from the building. In addition, the device may be painted the same colour of the building wall to which it is attached to enhance the unobtrusive nature of the device.
Referring to FIG. 4, illustrated is one embodiment of a portion showing a top mounting on the sill of a balcony. The base plate 13 is shown with the flat plate portion 19 mounted essentially flush against a top surface of a sill. The flat surface 23 of the protrusion 21 rests essentially flush against the outside wall of the sill. The arm 12 may be released from its operational position shown and rotated away from the base plate to its non-operational position directly beneath the protrusion 21.
Referring to FIG. 5, illustrated is the plate portion 19 with its upper surface 30 mounted essentially flush on a bottom sill. The protrusion 21 juts out from the sill and the arm 12 extends vertically upwards in its operational position and may be rotated away from the base plate 13 to its non-operational position directly beneath the protrusion.
It will be appreciated that each arm 12 is selectively pivotable between four positions without the pivot end of the arm interfering with the base plate 13 or intersecting the plane of the base plate. The first and second of those positions are the "up" operational protracted position and the "down" non-operational retracted position shown in FIG. 3, in which the arm extends substantially parallel to the base plate. The third of those positions is the operational protracted position shown in FIGS. 4 and 5 in which the arm extends substantially perpendicular to the base plate. The fourth position is not shown but is the non-operational retracted position referred to in the description of FIGS. 4 and 5 in which the arm also extends substantially parallel to the base plate but in the opposite direction.
Referring to FIG. 6, illustrated is a perspective view of a single arm bird deterring device according to the invention when installed on the back surface of a balcony wall, as described for FIG. 3. Shown is the "up" position in full lines and the "down" position in phantom. The base plate 13 is secured into an upstanding surface of a structure as described above. A wire 11 is shown threaded through holes in the arms 12 and the wire is secured to anchoring points 29.
The bird deterring device is maintained in position by tension on the hinge, controlled by torque, which is applied to the screw bolt 18 and wing nut 28. By releasing the tension on the hinge the bird deterring device is readily retracted to the "down" position as shown in FIG. 3.
It will be appreciated by an artisan that the hinge illustrated in FIGS. 1 and 2 may be replaced by a modified hinge, for example, a tension ratchet, quick release bolts and the like.
Although the above description refers to the use of bolts 29 for attachment of the base plate 13 to the building it should be appreciated that any conventional attachment means such as screws, nails, rivets or adhesive, etc., could be used instead.
According to a further aspect of the bird deterring device, more than two arms may be linked in sequence, wire being strung between the two or more arms. It will also be appreciated that although the FIGS. 1 and 2 show a wire threaded three times between the arms, the invention is not restricted to this embodiment. The invention allows for one or more wires to be linked in a suitable manner between two or more arms.
The plug 17 serves to hold the wire 11 in place by pinching the wire 11 against the wall of the hole 15. The mode in which the wire is attached to an arm is not at the essence of the invention. It will be appreciated that wire may be attached to an arm by many different methods, for example, by pinching between a screw and the arm, by glue, wedging between preformed nicks in the arms, etc. It will be appreciated that the wire 11 is also not at the essence of the invention and may be made of "fishing line" or another suitable material. While not being bound to any one form of commercialisation it is suggested that the invention may be sold in kit form wherein the purchaser would be responsible for additionally purchasing a suitable wire.
It is also within the scope of the invention for there to be a rigid linking member between two or more arms such that the mutual movement of two or more arms in unison into the up or down position is facilitated. The rigid linking member would be attached to the arms by conventional means. | A retractable device for deterring birds from landing, roosting or nesting on a surface of a building structure, the device including at least two holding mechanisms each having a mounting member to be attached to the building structure and an arm for securing wire between the wire holding mechanisms, the arms being pivotally connected at respective pivots to the mounting members and being selectively pivotable to an operational protracted position in which the arms and wire lie above the surface of the building structure and to a non-operational retracted position in which the arms and wire lie below the surface of the building structure. | 4 |
FIELD OF THE INVENTION
The present invention involves the chemical separation of enantiomers of 1,1′-spirobiindane-6,6′-diol derivatives.
BACKGROUND OF THE INVENTION
1,1′-Spirobiindane-6,6′-diol derivatives of Structure I:
have recently found substantial utility as, among other things, precursors for chiral polymers as disclosed in U.S. Pat. Nos. 5,856,422A and 6,288,206B1, precursors for macrocyclic compounds as disclosed in B. Kohler, et al., Chemistry—A European Journal, 7(14), 3000 (2001), precursors for chiral cyclophanes as disclosed in G. A. Consiglio, et al., Journal of Supramolecular Chemistry, 2(1–3), 293 (2003), and, more recently, precursors for the preparation of novel chiral dopants for nematic liquid crystal formulations as disclosed in U.S. patent application Ser. No. 10/737,457. Many of these applications require the use of enantiomerically enriched 1,1′-spirobiindane-6,6′-diol derivatives.
Methods for the efficient, environmentally responsible, large-scale preparation of these nonracemic derivatives are limited. Many syntheses of racemic 1,1′-spirobiindane-6,6′-diol derivatives have been disclosed, for example, in U.S. Pat. Nos. 4,701,566, 4,701,567, 4,791,234A, 6,132,641A, DE2645020, DE4027385 , J. Chem. Soc., 1962 , Revista Chimie, 34, 1069 (1983).418 . J. Org. Chem., 55, 4966(1990), J. Med. Chem., 43, 2031(2000), and J. Amer. Chem. Soc., 122, 2055(2000). These methods necessarily provide a 1:1 enantiomeric mixture of the derived 1,1′-spirobiindane-6,6′-diols. While methods for separating these mixtures do exist, they have proved wanting (vide infra).
Four general methods for the isolation of nonracemic compounds are known to those skilled in the art of organic chemistry: 1) chiral synthesis of individual enantiomers, 2) chiral chromatographic separation of racemates, 3) enzymatic resolutions of racemates, and 4) use of chiral auxiliaries for diastereomeric formation eventually leading to enantiomer separation. No methods for the direct synthesis of individual 1,1′-spirobiindane-6,6′-diol enantiomers are known. Further, the separation of racemic mixtures into their constituent enantiomers via chiral chromatography is primarily an analytical technique. While such technology for the “preparative” separation of racemic mixtures does exist, it is generally limited to a maximum of several grams of material, less than needed for many commercial applications. Further, the technology for these preparative separations is limited in structural scope, not readily allowing separation of the desired 1,1′-spirobiindane-6,6′-diol derivatives.
A method for the enzymatic separation of the enantiomers of a 1,1′-spirobiindane-6,6′-diol derivatives has been reported by R. J. Kazlauskas U.S. Pat. No. 4,879,421 and Journal of the American Chemical Society, 111(13), 4953–9(1989). This methodology employs (1) the preparation of achiral esters of the racemic 1,1′-spirobiindane-6,6′-diol derivatives, (2) the enantio-selective enzymatic hydrolysis of these racemic mixtures and (3) the eventual isolation of substantially enantiomerically enriched samples of the requisite 1,1′-spirobiindane-6,6′-diol derivatives after achiral chromatographic purification. While this technology has been demonstrated to be useful in the preparation of hundreds of grams of nonracemic 1,1′-spirobiindane-6,6′-diol derivatives, it suffers from substantial drawbacks. The initial step of Kazlauskas resolution requires the synthetic preparation of ester derivatives of the racemic 1,1′-spirobiindane-6,6′-diol. This material is then exposed to an appropriate enzyme formulation in aqueous media for several days. During this reaction phase, care must be taken to control reaction temperature and solution alkalinity. Careful analysis of reaction composition is also needed to alter reaction conditions, thus ensuring optimal conversion to nonracemic product. With the completion of the enzymatic reaction, multiple solvent extractions provide a nonracemic residue that must be further purified. Achiral silica gel chromatography, employing the environmentally suspect methylene chloride as an eluant, then provides the nonracemic products. Finally, saponification of residual ester groups provides the desired 1,1′-spirobiindane-6,6′-diol in good overall yield and high racemic purity. Application of this protocol to multi-kilogram production is limited, among other factors, by extended reaction times, multiple extractions leading to excessive solvent waste, large scale chromatographies, and the use of environmentally unacceptable chlorinated solvents.
Japanese chemists previously described the separation of a 1,1′-spirobiindane-6,6′-diol derivative using diastereomer formation, Bull. Soc. Chem. Japan, 44, 496 (1971). In that case, the requisite racemic spirobiindandiol substrate was reacted with a nonracemic chiral isocyanate to yield a mixture of diastereomeric mixture of urethane products. The mixture was then purified by repeated recrystallizations from benzene, a solvent designated a cancer suspect agent by the EPA. Finally, the desired spirobiindane was secured by chemical degradation of the chiral urethane groups.
Esters of phenols in general are very commonly encountered organic compounds. Within this context, they are meant to include structurally those derived from a 1,1′-spirobiindane-6,6′-diol and a carboxylic acid component. The acid component can be alkyl, cycloalkyl, aryl, alkyloxy (alkylcarbonic acid), cycloalkyl (cycloalkylcarbonic acid), or aryloxy (arylcarbonic acid). General methods for the preparation of phenyl esters are apparent to those skilled in the art. These method include: (1) reaction of the phenol with an acid chloride under basic conditions; (2) reaction of a phenol with a carboxylic acid under acidic conditions; (3) reaction of the phenol with a chloroformate; (4) reaction of a phenol and a carboxylic acid using a condensing agent; (5) reaction of the phenol with phosgene to prepare an intermediary phenyl chloroformate, that then can be condensed with a second phenol or alcohol, and similar transformations.
A variety of nonracemic chiral carboxylic acids, acid chlorides, chloroformates, and alcohols are available for the preparation of esters of potential use in separating 1,1′-spirobiindane-6,6′-diol enantiomers. These substrates may in turn be derived from natural sources, isolated chromatographically, prepared via enantio-selective methods, or otherwise purified. Most commonly, natural product derivatives are employed as chiral auxiliary agents.
Problem to be Solved
The known methods for separating enantiomers of 1,1′-spirobiindane-6,6′-diol necessarily require extensive chromatographies, long reaction times, and toxic solvents. For these reasons large-scale manufacturing separation of these enantiomers cannot be accomplished in an environmentally or economically acceptable way.
SUMMARY OF THE INVENTION
The present invention relates to a method for the chemical separation of the enantiomers of 1,1′-spirobiindane-6,6′-diol derivatives comprising providing a racemic chiral 1,1′-spirobiindane-6,6′-diol derivative, reacting a nonracemic chiral component with the racemic chiral 1,1′-spirobiindane-6,6′-diol derivative to afford a mixture of diastereomeric diesters, separating the mixture of diastereomeric diesters to provide a substantially pure individual diastereomeric diester, and chemically removing the ester groups from the substantially pure individual diastereomeric diester to provide a nonracemic chiral 1,1′-spirobiindane-6,6′-diol derivative.
ADVANTAGEOUS EFFECT OF THE INVENTION
The present invention includes several advantages, not all of which are incorporated in a single embodiment. This method is shown to avoid the need for long chemical reaction times, carefully controlled reaction conditions, detailed reaction analyses, chromatographic separations, and the use of chlorinated solvents. This method is a simple reaction/separation sequence affording chiral resolution of spirobiindanediols of use in preparing novel chiral dopants and other high value materials.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a novel method for the chemical separation of the enantiomers of 1,1′-spirobiindane-6,6′-diol derivatives. This method includes formation of chiral, nonracemic esters from the racemic 1,1′-spirobiindane-6,6′-diol derivatives, the separation of the so-derived mixture to provide nonracemic diastereomeric components, and finally, chemical removal of the appended ester groups to provide resolved enantiomerically enriched 1,1′-spirobiindane-6,6′-diol derivatives.
A variety of racemic 1,1′-spirobiindane-6,6′-diol derivatives can be obtained by means of known synthetic procedures or less likely from commercial sources. Such compounds useful in this process are generally described by compounds of Structure 2, wherein R 1 , R 2 , R 3 , and R 4 are independently hydrogen, or any carbon substituents, X groups are independently any substituent, and n are independently an integer 0–3 and wherein these substituents may for a ring. Preferably, all of the R 1 , R 2 , R 3 , and R 4 are hydrogen or lower alkyl group to include groups containing one to about eight carbon atoms, e.g. methyl ethyl, n-propyl, n-butyl, isobutyl, 2-pentyl, tert-pentyl and the like. It is most preferred that the R 1 and R 4 groups are hydrogen or methyl and the R 2 and R 3 groups are hydrogen and n=0.
Representative 1,1′-spirobiindane-6,6′-diol derivatives are presented herein. These examples are meant to be instructive not limiting.
I-1
I-2
I-3
I-4
I-5
I-6
I-7
I-8
I-9
I-10
I-11
I-12
I-13
The racemic 1,1′-spirobiindane-6,6′-diol is then suitably reacted with a chiral nonracemic component to form a mixture of diastereomeric diesters, that differ only in the configuration of the spiro-fused, stereogenic center. Suitable esters are described by Structure 3, wherein all of the substituents, save R E , are described as in Structure 2. In Structure 3, the two R E groups are the same. Also in structure 3, the integer m is the same and varies from 0 to 1. When m=1, the esters are carbonates.
Suitable R E substituents are chiral, substantially enantiomerically pure groups. These groups may be any suitable alkyl, cycloalkyl, alkaryl, aryl either substituted or unsubstituted. When the m=0 the esters are derived from a carboxylic acids; suitable acids include (+)-camphorcarboxylic acid, (−)-camphorcarboxylic acid, podocarpic acid, (+)-cis-2-benzamidocyclohexanecarboxylic acid, dihydroabietic acid, abietic acid, (+)-camphoric acid, and (−)-camphanic acid. Preferably, the —O—R E (i.e., m=1) groups are cycloalkyl to include those derived from the conjugate bases of enantiomerically enriched menthol, fenchol, neomenthol, isomenthol, 8-phenylmenthol, borneol, trans-2-phenylcyclohexan-1-ol, isopinocampheol, isoborneol, endo-2-norborneol, dihydrocarveol, isopulegol, trans-2-tert-butylcyclohexan-1-ol, cholesterol, exo-6-hydroxytropinone trans-pinocarveol. Most suitably, the groups —O—R E (i.e., m=1) are either one or the other enantiomer of menthol, generally designated either (+)-menthyl or (−)-menthyl:
The requisite diastereomer mixtures are prepared via condensation of the racemic 1,1′-spirobiindane-6,6′-diol directly with the nonracemic chiral acid component or with a suitably activated acid component usually in an organic solvent. Such activated acid components include carboxylic acid chlorides, carboxylic acid bromides, chloroformates, carboxylic acid anhydrides, mixed carboxylic acid-sulfonic acid anhydrides, bromoformates, mixed carbonic acid-sulfonic acid anhydrides.
Direct condensations of racemic 1,1′-spirobiindane-6,6′-diol derivatives with nonracemic chiral acids can be induced via strong acids or using condensing agents. Strong acids may include minerals acids such as sulfuric acid, phosphoric acid, hydrochloric acid or organic acids such as methanesulfonic acid, trifluoromethanesulfonic acid, trifluoroacetic acid, toluenesulfonic acid, or protic acids of similar acid strength. Condensing agents may include dicyclohexylcarbodiimide, diisopropylcarbodiimide, diethyl azodicarboxylate/triphenylphosphine, diisopropyl azodicarboxylate/triphenylphosphine, and similar reagents.
Alternatively, the racemic 1,1′-spirobiindane-6,6′-diol derivatives may be converted to their corresponding bis-chloroformate, then condensed with suitable nonracemic alcohols under basic conditions to provide the desired mixture of diastereomeric diesters. Typically such bis-chloroformates may be formed from the 1,1′-spirobiindane-6,6′-diol derivatives using phosgene, or a phosgene equivalent such as trichloromethyl chloroformate (diphosgene) or bis-trichloromethyl carbonate (triphosgene), under neutral, acidic or basic conditions. The so produced racemic bis-chloroformates they may be reacted with suitable nonracemic alcohols, under basic conditions, to provide the desired mixture of diastereomeric bis-carbonates.
The procedures employed to prepare the mixture of diastereomeric diesters outlined above most usually are performed in an organic solvent or solvent mixture. Conveniently, on a laboratory-sized scale, these reactions are often run in chlorocarbon solvents, such as methylene chloride. For larger scale reactions, perhaps in a manufacturing environment, a variety of alternative solvent might readily be substituted. Typical alternative solvents include tetrahydrofuran (THF), dioxane, isopropyl ether (IPE), 1,2-dimethoxyethane (DME), ethyl acetate, propyl acetate, butyl acetate, acetonitrile, propionitrile, butyronitrile, toluene, xylenes, heptanes, N,N-dimethylformamide (DMF), N,N-dimethylacetamide (DMA), N-methylpyrrolidone (NMP), pyridine, or mixtures of such solvents.
Bases useful in the reactions of the invention include organic bases such as triethylamine, pyridine, diisopropylethylamine, 1,1,3,3-tetramethylguanadine, 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), dicyclohexylamine, and inorganic bases such as sodium bicarbonate, potassium bicarbonate, sodium carbonate, potassium carbonate, potassium phosphate, cesium carbonate, sodium acetate.
The suitably prepared mixture of diastereomeric diesters then can be separated via one of a variety of techniques known to those practiced in the art. These methods include trituration, in this case defined as stirring the material of interest with a designated organic liquid so as to induce crystallization, dissolve impurities, or allow break-up of a crystalline mass, fractional crystallization, recrystallization, achiral chromatography, high performance (or pressure) liquid chromatography (HPLC), flash chromatography. Preferably, the separation of the diastereomeric esters proceeds via trituration of the mixture with a suitable organic solvent to induce crystallization of one diastereomeric diester, followed by filtration of the solid and drying of the crystallized diastereomeric diester.
Finally, the chiral ester groups pendant on the core of the nonracemic 1,1′-spirobiindane-6,6′-diol diastereomeric diester are removed to provide the desired nonracemic 1,1′-spirobiindane-6,6′-diol enantiomers. Many methods for such ester removal are known to those practiced in the art. Of particular note are hydrolyses under strongly acid or basic aqueous conditions, transesterification usually employing acidic reagents, nucleophilic displacements, ester reductions, and similar methods. Hydrolytic conditions usually entail reaction of the ester with bases, (for example, lithium hydroxide, sodium hydroxide, potassium hydroxide or cesium hydroxide) or mineral acid (for example, sulfuric acid, phosphoric acid, hydrochloric acid) in water or mixed water/solvent reaction media. Suitable solvents include methanol, ethanol, 2-propanol, 1-propanol, THF, DMF, DMA, NMP, DME, ethylene glycol or mixtures of these solvents. Transesterifications, in this case, would usually involve reaction of the bis-ester with an excess of alcohol under acidic conditions, such that a nonracemic 1,1′-spirobiindane-6,6′-diol bis-ester would transfer its acid components to the hydroxylic solvent producing a new chiral esters and the nonracemic 1,1′-spirobiindane-6,6′-diol derivative. Suitable hydroxylic solvents include methanol, ethanol, 2-propanol, 1-propanol, ethylene glycol. Further, a suitable co-solvent may be added to improve reactant solubility.
Several examples of the invention are presented herein as demonstration of the invented and are not meant to be limiting.
EXAMPLES
Example 1
Step 1: Preparation of Racemic Chiral 1,1′-spirobiindane-6,6′-diol Derivative (±)-I–1
The synthesis of representative diol derivative compounds used in the invention, as shown in Scheme 1, begins with preparation of racemic (±)-I-1, followed by chiral resolution of this enantiomeric mixture to provide (+)-I-1. The preparation of racemic 3,3,3′,3′-tetramethyl-1,1′-spirobiindan-6,6′-diol employed a minor variant of the method described by Faler and Lynch, EP264026A1. This synthetic route and its subsequent partial enantiomeric resolution are outlined in Scheme 1.
A mixture of bis-phenol A (Int-1; CAS 80-05-7; 100 g, 0.438 mole) and methanesulfonic acid (5 mL) was heated at 135° C. for three hours then cautiously poured into 550 mL water with stirring. After stirring a short while the liquid was decanted and the remaining solid diluted with 350 mL water and the stirring continued. This procedure was repeated twice further to provide a semi-solid mass. The damped solid was heated to reflux with 150 mL methylene chloride for one hour then chilled. The solid was collected, washed with minimal cold methylene chloride and ligroin to provide (±)-I-1 as a white solid 29.1 g (65%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
Step 2: Preparation of Diastereomeric Diester Mixture:
A solution of (±)-I-1 (12.3 g; 40 mmol), triethylamine (TEA; 20 mL, 144 mmol), and 4-dimethylaminopyridine (DMAP; 1 g, 8 mmol) in 200 mL methylene chloride was treated over circa ten minutes with a solution of (−)-menthyl chloroformate (i.e. the chloroformate derived from (−)-menthol; CAS 14602-86-9; 18 mL, 84 mmol) in 5 mL methylene chloride. The resulting mixture stirred at ambient temperature for three hours then was washed with dilute hydrochloric acid, dried with sodium sulfate, filtered and concentrated in vacuo. The glassy residue contained an equimolar mixture of the diastereomeric diesters Int-2 and Int-3 as assessed by proton NMR spectroscopy.
Step 3: Separation of Diastereomeric Diester
The glassy residue, containing an equimolar mixture of the diastereomeric diesters Int-2 and Int-3 as assessed by proton NMR spectroscopy, was dissolved in 150 mL heptanes. Shortly, crystallization initiated and the slurry stirred at ambient temperature for twenty hours. The slurry was chilled in an ice water bath then filtered; the solids washed with minimal cold heptanes and low-boiling ligroin to provide Int-2 as a colorless solid, 9.46 g (35%; 70% based on single diastereomeric diester). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. High field NMR detected none of the alternative diastereomeric diester, Int-3.
Step 4: Removal of Ester Groups
A solution of Int-2 (9.00 g, 13.4 mmol) and hydrazine monohydrate (4.6 mL, 95 mmol) in 85 mL tetrahydrofuran (THF) was heated at reflux for three hours then portioned between dilute hydrochloric acid and ethyl acetate. The organic layer wash dried with sodium sulfate, filtered and concentrated in vacuo to provide an oil.
Step 5: Optional Further Purification of Nonracemic Chiral 1,1′-spirobiindane-6,6′-diol Derivative
Two silica gel chromatographies, first eluting with mixture of methylene chloride and ethyl acetate, then secondly, eluting with mixtures of heptanes and isopropyl ether, gave a purified oil. Trituration with IPE/heptanes, followed by filtration and drying, finally yielded (+)-I-1 as a colorless solid, 3.66 g (88.6%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Chiral HPLC analysis indicate an % ee of >98%; Polarimetry provided [α] D 23 =+37.4° (methanol, c=0.010).
Example 2
Step 1: Preparation of Racemic Chiral 1,1′-spirobiindane-6,6′-diol Derivative and
Step 2: Preparation of Diastereomeric Diester Mixture:
A second run (1.9× the original scale) of the chiral resolution of (±)-I-1 was accomplished as in Example 1, except the crude reaction product was not chromatographed.
Step 3: Separation of Diastereomeric Diester Mixture
The reaction product was directly dissolved in 250 mL low-boiling ligroin (pentanes) and chilled in an acetone/ice (ca. −20° C.) bath to induce crystallization. After two hours the cold slurry was filtered and the solid washed with minimal pentanes. The solid diastereomeric diester Int-2 was obtained as a colorless solid in 42% (84% based on single diastereomeric diester) yield. This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Analytical HPLC indicated 99.2% diastereomeric purity.
Step 4: Removal of Ester Groups
A second run (1.6× the original scale) of the preparation of (+)-I-1 was accomplished as in Example 1, except the crude reaction product was not chromatographed, but rather triturated with isopropyl ether to provide (+)-I-1 as a colorless solid (5.46 g, 85%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Chiral HPLC analysis indicated 99.9% enantiomer purity.
Example 3
Step 1: Preparation of Racemic Chiral 1,1′-spirobiindane-6,6′-diol Derivative and
Step 2: Preparation of Diastereomeric Diester Mixture:
Another run (1.4× the original scale) of the chiral resolution of (±)-I-1 was accomplished as in Example 1, except (+)-menthyl chlororformate (i.e. the chloroformate derived from (+)-menthol; CAS 7635–54–3) the crude reaction product was not chromatographed.
Step 3: Separation of Diastereomeric Diester Mixture
The crude reaction product was directly dissolved in 250 mL low-boiling ligroin (pentanes) and chilled in an acetone/ice (ca. −20° C.) bath to induce crystallization. After two hours the cold slurry was filtered and the solid washed with minimal pentanes. The solid diastereomeric diester Int-4 was obtained as a colorless solid in 36% (72% based on single diastereomeric diester) yield. This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Proton NMR indicated none of the alternative diastereomeric diester.
Step 4: Removal of Ester Groups
A run of the preparation of (−)-I-1 was accomplished as for its epimer in Example 1, except the crude reaction product was not chromatographed, but rather triturated with heptanes to provide (−)-I-1 as a colorless solid (5.29 g, 89%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Chiral HPLC analysis indicated 99.1% enantiomer purity.
Example 4
Step 1: Preparation of Racemic Chiral 1,1′-spirobiindane-6,6′-diol Derivative (±)-Int-8
A mixture Montmorillonite K10 clay (CAS 1318-93-0; 20 g, dried ≧100° C. in vacuo) and 100 mL xylenes were refluxed under a Dean-Stark trap for twenty minutes, then 1,5-(4-methoxyphenyl)-3-pentanone (Int-6; CAS 74882-32-9, prepared via standard synthetic procedures outlined in Scheme 2; 4.00 g, 13.4 mmol) was added and the reflux continued for twenty hours. The mixture was briefly cooled and then filtered through diatomaceous earth. The solids were washed with toluene (100 mL in portions). The combined filtrates were concentrated in vacuo to provide a crude solid. This material was carefully chromatographed on silica gel, eluting with mixtures of heptanes and ethyl acetate, to provide a purified semi-solid. Trituration of this material with cold isopropyl ether then provided Int-7 as a colorless solid, 0.75 g (20%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
A solution of Int-7 (0.56 g, 2.0 mmol) in 10 mL methylene chloride was chilled in an ice-acetone bath then treated with boron tribromide (0.45 mL, 4.8 mmol). The mixture stirred at ambient temperature for one hour then was cooled and the reaction quenched by the cautious addition of 5 mL water. The organics were separated, dried with sodium sulfate, filtered and concentrated in vacuo. The residue was treated with isopropyl ether and heptane to induce crystal formation. These solvents were removed in vacuo to provide Int-8 as a colorless solid, 0.5 g (circa 100%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure.
Step 2: Preparation of Diastereomeric Diester Mixture:
A slurry of Int-8 (0.45 g, 1.8 mmol) in 15 mL methylene chloride, at ambient temperature, was sequentially treated menthyl chloroformate (0.8 mL, 3.7 mmol), triethylamine (0.9 mL, 6.5 mmol) and DMAP (0.05 g, 0.4 mmol). The mixture was stirred at ambient temperature for one hour, and then washed with dilute hydrochloric acid. The organics were dried with sodium sulfate, filtered and concentrated in vacuo. The residue was chromatographed on silica gel, eluting with methylene chloride, top provide the expected mixture of diastereomeric diesters as a colorless oil, 1.1 g (circa 100%). NMR analysis indicated an equimolar mixture of diastereomeric diesters.
Step 3: Separation of Diastereomeric Diester Mixture
This residue was dissolved in 15 mL heptanes after which crystallization initiated. The mixture stirred at ambient temperature for thirty minutes then was filtered, to yield Int-9 as a colorless solid, 0.39 g (35%, 71% based on a single diastereomeric diester). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. Careful NMR analysis indicated the presence of a single diastereomeric diester.
Step 4: Removal of Ester Groups—Hydrazine Method
A solution of Int-9 (0.35 g, 0.57 mmol) in 7.5 mL THF was treated with hydrazine monohydrate (0.25 mL, 5.2 mmol) then heated at reflux for thirty minutes. Additional hydrazine monohydrate was added (0.15 mL, 3.1 mmol) and mix heated another hour. The mix stirred at ambient temperature overnight then was partitioned between dilute hydrochloric acid and ethyl acetate. The organic layer was dried with sodium sulfate, filtered and concentrated in vacuo to provide a glassy residue. Silica gel chromatography, eluting with mixtures of methylene chloride and ethyl acetate, gave a purified oil. This oil was dissolved ethyl acetate then washed with dilute aqueous sodium hydroxide. The aqueous layer was acidified with hydrochloric acid and extracted with ethyl acetate. The organics were dried, filtered, and concentrated to provide I-2 as a colorless oil, 0.14 g ((100%). This material proved chromatically homogenous and displayed spectral characteristics consistent with its assigned structure. The enantiomeric excess was taken to be circa 1 based upon NMR of the purified diastereomeric diester.
Step 4: Removal of Ester Groups—Alkaline Hydrolysis Method:
A mixture of Int-9 (43 mg, 0.0070 mmol) in a mixture of 5 mL methanol and 3 mL THF with sodium hydroxide (0.3 mL of a 10 Wt % aqueous solution) was refluxed for 3 h. The mixture was poured into dilute aqueous sodium hydroxide and the mixture extracted with ethyl acetate. The ethyl acetate was further extracted with portions of 10 Wt % aqueous sodium hydroxide (four times 5 mL). The aqueous portions were made acidic (pH≦2) by the addition of concentrated hydrochloric acid. Ethyl acetate extractive workup provided, after drying and concentration in vacuo, I-2 as an oil (14 mg, 78%). NMR analysis confirmed the assigned structure. Chiral HPLC analysis indicated 98.8% enantiomeric purity.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | The present invention relates to a method for the chemical separation of the enantiomers of 1,1′-spirobiindane-6,6′-diol derivatives comprising providing a racemic chiral 1,1′-spirobiindane-6,6′-diol derivative, reacting a nonracemic chiral component with the racemic chiral 1,1′-spirobiindane-6,6′-diol derivative to afford a mixture of diastereomeric diesters, separating the mixture of diastereomeric diesters to provide a substantially pure individual diastereomeric diester, and chemically removing the ester groups from the substantially pure individual diastereomeric diester to provide a nonracemic chiral 1,1′-spirobiindane-6,6′-diol derivative. | 2 |
FIELD OF THE INVENTION
This invention relates to a multi-beam photoelectric safeguard system and, more particularly, to a method of installing a safeguard system including main light emitting and detecting devices and sub light emitting and detecting devices and a method of adjusting their optical axes.
BACKGROUND OF THE INVENTION
Multi-beam photoelectric safeguard systems, comprising a light emitting device including a plurality of aligned light emitting elements and a light detecting device including a plurality of corresponding photodetectors as one unit, are commonly employed to detect the intrusion of an optical obstacle in a wide detection area. Multi-beam photoelectric safeguard systems are typically used to make protective fences, i.e. light curtains, along boundaries of prohibited areas where machine tools, punching machines, pressing machines, casting machines, automatic controllers and the like are installed, so that, if a part of the body of an operator, for example, intrudes into such a prohibited area, the system detects the intrusion and immediately stops the machine and/or gives a warning signal.
Regarding relative placement between the light emitting device and the light detecting device of a multi-beam photoelectric safeguard system, in case a machinery 1 such as a press as shown in FIG. 1 includes a projecting portion 2 projecting toward the operator, one of solutions is to place the safeguard system 3 in a position beyond the proximal end of the projecting portion 2 where the safeguard system does not interfere the projection 2 at all.
This placement, however, increases the horizontal distance X 1 from the work center O of the machinery 1 to the safeguard system 3 (light curtain), hence increases the total area for installment of the press, for example, including the area for its safeguard system, and therefore decreases the working efficiency of the press.
In case the machinery 1 includes the projecting portion 2 that projects toward the operator, another solution is to place the safeguard system 3 as shown in FIGS. 2 and 3. In the conventional example shown here, the safeguard system 3 (light curtain) is positioned close to the machinery 1 , and rearranged beforehand to exclude from effective detection the zone 4 encountering the projecting portion 2 , i.e. the zone 4 where some of optical axes 5 forming the light curtain are optically blocked by the projecting portion 2 . That is, a blanking function, which excludes the zone 4 encountering the projection 2 as a non-detection area beforehand, permits the safeguard system 3 (light curtain) to be placed even at a position where it interferes the projecting portion 2 .
In this configuration, since the protective fence, i.e. light curtain, can be positioned closely to the machinery 1 (X 2 <X 1 ) so as to keep a safety distance as small as possible with respect to the machinery 1 , the working efficiency can be improved.
However, this approach relying on invalidating some of the optical axes 5 in the zone 4 excludes the full extension of the zone 4 from detection, including a section or sections at one or both sides of the projecting portion, although there is equally the possibility that an optical obstacle intrudes into the prohibited are through that section. To compensate this defect, another safeguard measure has to be employed, such as, for example, covering each such section of the zone 4 with a physical fence 6 such as a metal plate or net as shown in FIG. 4 .
Japanese Patent Laid-Open Publication No. S63-43099 proposes a multi-beam photoelectric safeguard system contemplating the existence of a projecting portion as discussed above. The safeguard system disclosed in this publication is comprised of a pair of light emitting and detecting devices including a plurality of light emitting elements and complementary photodetectors, respectively, and a pair of reflection mirrors disposed adjacent to the projecting portion so that, in the zone encountering the projecting portion, a light curtain is made at one or opposite sides of the projecting portion by reflecting light beams from the light emitting and detecting devices at the reflection mirrors and receiving the reflected light beams at the same light emitting and detecting devices.
With the safeguard system taught by that publication, however, it is difficult to adjust the optical axes between the light emitting and detecting devices and the optical alignment of respective light emitting elements and photodetectors with associated reflection mirrors. Especially when the optical axes are arrayed closely, the difficulty becomes greater. Furthermore, since each of the light emitting and detecting devices has to include light emitting elements or photodetectors for emitting or detecting light beams to and from the reflection mirrors, the light emitting and detecting devices inevitably become bulky.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a method of installation and a method of adjusting optical axes of a multi-beam photoelectric safeguard system capable of positioning a light curtain made of closely arrayed optical axes very closely to a machinery or equipment such as a press, which requires the safeguard system.
A further object of the invention is to provide a method of installation and a method of adjusting optical axes of a multi-beam photoelectric safeguard system which is suitable for use with a machinery or equipment such as a press, which requires the safeguard system and includes a portion projecting toward the operator, and can make a light curtain closely to the press with no invalidated zone.
A still further object of the invention is to provide a method of installation of a multi-beam photoelectric safeguard system for making a light curtain without non-detection zones around an interfering object by using a main light emitting device and a sub light detecting device operable according to a basic operation sequence to sequentially emit light beams from the main light emitting device at predetermined timings, which can simultaneously generate a new operation sequence incorporating sub light emitting and detecting devices as well.
Those objects of the invention can be accomplished by various aspects of the invention.
According to an aspect of the invention, there is provided a method of installing a multi-beam photoelectric safeguard system for making a light curtain with a number of light beams around an interfering object, the multi-beam photoelectric safeguard system including:
a main light emitting device having a plurality of light emitting elements aligned in an array at equal intervals;
a main light detecting device disposed in an opposed relationship with the main light emitting device and having a plurality of photodetectors equal in number to the light emitting elements and arranged in an array at regular intervals;
a sub light detecting device disposed adjacent to one side of the interfering object interrupting a light beam of at least one optical axis of the light curtain, and including at least one photodetector capable of detecting a light beam from the main light emitting device;
a sub light emitting device disposed adjacent to the other side of the interfering object and capable of emitting a light beam toward the main light detecting device; and
the light curtain including a main detection area defined between the main light emitting device and the main light detecting device, a first sub detection area defined between the main light emitting device and the sub light detecting device, and a second sub detection area defined between the sub light emitting device and the main light detecting device,
the method comprising:
(a) positioning the main light emitting device and the main light detecting device relative to each other and identifying a blanking optical axis interrupted by the interfering object among the light beams between the main light emitting device and the main light detecting device;
(b) placing the sub light detecting device adjacent to one side of the interfering object and thereafter positioning same relative to the main light emitting device by moving the sub light detecting device; and
(c) placing the sub light emitting device adjacent to the other side of the interfering object and thereafter positioning same relative to the main light detecting device by moving the sub light emitting device.
In a preferred embodiment of the invention, relative positioning of the main light emitting and detecting devices and adjustment of their optical axes may be carried out either without any interfering object or under the existence of such object.
In an embodiment of the invention, an optical axis adjustment display or optical axis adjustment display lamp is typically provided on the main light emitting device and/or main light detecting device. The operator can confirm completion of relative positioning of the main light emitting and detecting devices and adjustment of their optical axes by watching the optical axis adjustment display. Similarly for sub light detecting and emitting devices, an optical axis adjustment display or display lamp is preferably provided on the sub light detecting device and or sub light emitting device.
In another preferred embodiment, a controller for substantially controlling light emitting and detecting devices of the safeguard system may be provided, and an optical axis adjustment display or display lamp may be provided on the controller such that adjustment of optical axes of all light emitting and detecting devices contained in the safeguard system can be confirmed totally on the optical axis adjustment display of the controller.
In another preferred embodiment, the main light emitting and detecting devices forms a basic unit of the safeguard system, and sub light emitting and detecting devices may be added as an optional unit if a user requests. The main light emitting and detecting devices as the basic unit operate according to a preset basic operation sequence. In the basic sequence, light emitting elements contained in the main light emitting device are sequentially activated at predetermined timings for a predetermined length of time, individually.
When the sub light detecting and emitting devices are added to the main light emitting and detecting device activated by the basic operation sequence, by identifying the blanking optical axis, it is possible to automatically generate a modified operation sequence for additionally determining operations of the sub light emitting device on the basis of the blanking optical axis.
When optical axes are again adjusted upon maintenance after installation of the multi-beam photoelectric safeguard system suitable for use of the present invention, it is advantageous to first adjust optical axes between the main light emitting and detecting devices by moving them relative to each other, next adjust the optical axes between the main light emitting device and the sub light detecting device by moving the latter, and finally adjust optical axes between the sub light emitting device and the main light detecting device by moving the former.
As another method of optical axis adjustment, it is possible to first adjust optical axes between the main light emitting and detecting devices by moving them relative to each other, next adjust optical axes between the sub light emitting device and the main light detecting device by moving the former, and finally adjust the optical axes between the main light emitting device and the sub light detecting device by moving the latter.
These and other objects and advantages of the invention will appear from the following description of preferred embodiments mainly in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a conventional multi-beam photoelectric safeguard system from its side angle to explain a way of installation thereof;
FIG. 2 is a diagram of a conventional multi-beam photoelectric safeguard system from its side angle to explain another way of installation;
FIG. 3 is a diagram illustrating the conventional multi-beam photoelectric safeguard system of FIG. 2 from its front angle to explain the same way of installation;
FIG. 4 is a diagram illustrating a conventional system covering a non-detection area with a metal net or the like;
FIG. 5 is a diagram schematically showing the entire configuration of a multi-beam photoelectric safeguard system taken as an example for use of the present invention;
FIG. 6 is a diagram illustrating the safeguard system according to the embodiment of FIG. 5 from its side angle to show a way of installation thereof;
FIG. 7 is a diagram for explaining a main detection area defined between a main light emitting device and a main light detecting device, a first sub detection area defined between the main light emitting device and a sub light detecting device, and a second sub area defined between a sub light emitting device and the main light detecting device in the safeguard system shown in FIG. 5;
FIG. 8 is a diagram schematically showing the entire configuration of the multi-beam photoelectric safeguard system shown in FIG. 5;
FIG. 9 is a diagram for explaining an example of optical axis adjustment display lamp or optical axis adjustment display provided in a multi-beam photoelectric safeguard system related to the present invention;
FIG. 10 is a diagram for explaining another example of optical axis adjustment display lamp or optical axis adjustment display provided in a multi-beam photoelectric safeguard system related to the present invention;
FIG. 11 is a block diagram of the main light emitting device and the main light detecting device constituting the basic units of the multi-beam photoelectric safeguard system shown in FIG. 5;
FIG. 12 is a block diagram of the sub light detecting device involved in the safeguard system shown in FIG. 5;
FIG. 13 is a block diagram of the sub light emitting device involved in the safeguard system shown in FIG. 5;
FIG. 14 is a diagram for explaining a basic operation sequence of the main light emitting and detecting devices as the basic unit of the main light detecting device shown in FIG. 5;
FIG. 15 is a diagram for explaining a multi-detection operation sequence or modified operation sequence of the safeguard system shown in FIG. 5;
FIG. 16 is a diagram for explaining a multi-detection operation sequence or modified operation sequence as another example related to FIG. 5;
FIG. 17 is a diagram for explaining the situation of intrusion of an optical obstacle in the main detection area made by the safeguard system shown in FIG. 5;
FIG. 18 is a diagram for explaining the situation of intrusion of an optical obstacle in the first sub detection area made by the safeguard system shown in FIG. 5;
FIG. 19 is a diagram for explaining the situation of intrusion of an optical obstacle in the second sub detection area made by the safeguard system shown in FIG. 5;
FIG. 20 is a diagram illustrating the entire configuration of the multi-beam photoelectric safeguard system shown in FIG. 5;
FIG. 21 is a flowchart of procedures in a teaching mode for automatically generating the modified operation sequence;
FIG. 22 is a diagram for explaining the first step of procedures according to the invention for optical axis adjustment of the light emitting and detecting devices of the multi-beam photoelectric safeguard system;
FIG. 23 is a diagram for explaining the second step of procedures according to the invention for optical axis adjustment of the light emitting and detecting devices of the multi-beam photoelectric safeguard system;
FIG. 24 is a diagram for explaining the fourth step of procedures according to the invention for optical axis adjustment of the light emitting and detecting devices of the multi-beam photoelectric safeguard system;
FIG. 25 is a diagram for explaining the fifth step of procedures according to the invention for optical axis adjustment of the light emitting and detecting devices of the multi-beam photoelectric safeguard system;
FIG. 26 is a diagram for explaining the sixth step of procedures according to the invention for optical axis adjustment of the light emitting and detecting devices of the multi-beam photoelectric safeguard system;
FIG. 27 is a diagram for explaining a spacer preferably used in the fourth step of procedures according to the invention for optical axis adjustment of the light emitting and detecting devices of the multi-beam photoelectric safeguard system; and
FIG. 28 is a diagram for explaining the first step of alternative procedures according to the invention for optical axis adjustment of light emitting and detecting devices of a multi-axis photoelectric safeguard system.
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the invention will now be explained below with reference to the drawings.
Referring to FIG. 5, the multi-beam photoelectric safeguard system 100 includes a main light emitting device 11 and a complementary main light detecting device 12 as the basic units thereof. Both the main light emitting device 11 and the main light detecting device 12 constituting the basic units can be extended by connecting one or more additional such devices in series or in parallel, respectively. The safeguard system 100 further includes a sub light detecting device 13 complementary with an opposed section of the main light emitting device 11 , and a sub light emitting device 14 complementary with an opposed section of the main light detecting device 12 .
The main light emitting device 11 has an elongate case 11 a . N (eight in this embodiment) light emitting elements (not shown), which may be light emitting diodes (LEDs), are arranged in the case 11 a at regular intervals in an array along the lengthwise (longitudinal) direction thereof. The interval of the light emitting elements may be 20 mm, for example, although it may be determined otherwise, either longer or shorter.
The main light detecting device 12 also has an elongate case 12 a , and photodetectors (not shown) equal in number to the light emitting elements (eight in this embodiment) are arranged in the case 12 a at regular intervals. The interval of the adjacent photodetectors is equal to that of the light emitting elements. If the interval of the light emitting elements is 20 mm, then the interval of the photodetectors is also 20 mm.
The sub light detecting device 13 has a relatively short case 13 a , and one or more light photodetectors (not shown) less than the light emitting elements or photodetectors of the main light emitting device 11 or main light detecting device 12 are arranged in the case 13 a in an array. In this embodiment, two photodetectors are provided, and their interval is equal to that of the light emitting elements of the main light emitting device 11 . Thus, if the interval of the light emitting elements of the main light emitting device is 20 mm, the interval of the photodetectors of the sub light detecting device 13 is also 20 mm.
The sub light emitting device 14 includes a relatively short case 14 a , and one or more light emitting elements (not shown) equal in number to the photodetector or photodetectors of the sub light detecting device 13 are arranged in the case 14 a in an array. Here again, LEDs are typically used as the light emitting elements. Two photodetectors are provided in this embodiment, and their interval is equal to that of the photodetectors of the main light detecting device 12 . Thus, if the interval of the photodetectors of the main light detecting device 12 is 20 mm, the interval of the light emitting elements of the sub light emitting device 14 is also 20 mm.
The numbers from 1 to 8 shown in FIG. 5 represent the numbers of optical axes between the main light emitting device 11 and the main light detecting device 12 . As seen from FIG. 5, the main light emitting device 11 and the main light detecting device 12 are placed in an opposed relation on a common plane to emit and receive light beams that form a light curtain (FIG. 7 ). The area where the light beams run between the light emitting and detecting devices 11 , 12 is herein named the main detection area 15 . The sub light detecting device 13 and the sub light emitting device 14 are placed to interrupt one or more optical axes between the main light emitting and detecting devices 11 , 12 to define the first sub detection area 16 between an opposed section of the main light emitting device 11 and the sub light detecting device 13 , and the second sub detection area 17 between the sub light emitting device 14 and an opposed section of the main light detecting device 12 (FIG. 7 ).
More specifically, the sub light detecting device 13 is placed close to one side surface of the a projecting portion 21 that projects toward an operator of a machinery 20 , and opposed to the main light emitting device 11 to define the first sub detection area 16 together with opposed light emitting elements of the main light emitting device 11 . The sub light emitting device 14 is placed close to the opposite side surface of the projecting portion 21 , and opposed to the main light detecting device 12 to define the second sub detection area 17 together with opposed photodetectors of the main light detecting device 12 .
As a result, light beams traveling in the main detection area 15 and the sub detection areas 16 , 17 form a light curtain all around the non-detection area defined between the sub light detecting and emitting devices 13 , 14 and occupied by the projecting portion 21 of the press 20 .
FIGS. 5 and 7 illustrate the sub light detecting device 13 and the sub light emitting device 14 as lying to partly take over one or more of optical axes between the main light emitting and detecting devices 11 , 12 at opposite sides of the non-detection area defined between the sub light detecting and emitting devices 13 , 14 . In the drawings, the sub light detecting and emitting devices 13 , 14 are positioned to partly take over the third and fourth optical axes; however, their position relative to the optical axes is determined, depending on the position of the projecting portion 21 . The number of the pairs of photodetectors and light emitting elements in the sub light detecting and emitting devices 13 , 14 is determined in accordance with the size of the projecting portion 21 or other obstacle to equally compensate for the number of optical axes between the main light emitting and detecting devices 11 , 12 , which will be optically blocked by the projecting portion 21 .
The main light emitting device 11 , main light detecting device 12 , sub light detecting device 13 and sub light emitting device 14 are connected altogether via a communication line or signal line 22 .
Referring to FIG. 8, the main light emitting and detecting devices 11 , 12 each include an optical axis adjustment display 30 composed of a plurality of light emitting diode (LED) segments vertically aligned side by side. Here are used dichromatic light emitting diodes that can emit, for example, red and green light. Each of the main light emitting device 11 and the main light detecting device 12 also has an output display such as ON/OFF light using LED that normally emits green light, for example, and otherwise emits red light, for example, when any unexpected optical axes are blocked or detected, or when the system itself fails, for example.
The optical axis adjustment display, or optical axis adjustment display lamp, 30 composed of a plurality of light emitting diode segments may be used in any appropriate mode of display. Typically, when all beams of all optical axes enter into the main light detecting device 12 , all LED segments may emit green light. Then, if part of the optical axes are blocked, a number of segments proportional to the blocked optical axes, i.e. proportional to the light beams failing to reach the main light emitting device 12 , may emit red light sequentially from the bottom one, and a number of segments corresponding to the number of the blocked optical axes turn off from the top one. That is, the optical axis adjustment display 30 displays a bar type representation in which a red bar extends upward as the ratio of incident beams becomes higher, or in response to the degree of optical axis adjustment, in other words, the ratio between interrupted beams and detected beams, typically for facilitating an operator to confirm accurate alignment between the light emitting elements and photodetectors of the light emitting and detecting devices 11 , 12 upon installing the safeguard system 100 on site.
The sub light emitting device 13 and the sub light detecting device 14 each include a optical axis adjustment display 32 having substantially the same function as the optical axis adjustment display or display lamp 30 already explained.
The optical axis adjustment displays 30 of the main light emitting and detecting devices 11 , 12 and/or the optical axis adjustment displays 30 of the sub light detecting and emitting devices 32 may be any of the below-listed conventional types.
(1) A display lamp turned on or off when optical axis adjustment is confirmed by detection of light beams of all optical axes;
(2) A display lamp changed in color from red to green, for example, when optical axis adjustment is confirmed by detection of light beams of all optical axes;
(3) A display lamp having a plurality of LEDs that are selectively, cumulatively turned on or off in response to the intensity of light detected by the light detecting device;
(4) A display lamp changed in flickering speed in response to the ratio between the interrupted optical axes and the other optical axes of detected light beams;
(5) A display lamp changed in flickering speed in response to the intensity of light detected by the light detecting device;
(6) A set of display lamps individually associated with respective optical axes to individually represent interruption or detection of their own associated optical axes;
(7) A set of display lamps, each associated with several divisional blocks of optical axes made by dividing a number of optical axes between the light emitting and detecting devices, to represent the interruption or detection status of its own associated block.
FIG. 9 shows an example of the optical axis adjustment display 30 , which is a set of display lamps 33 , associated with individual optical axes, respectively, as listed in (6) above. FIG. 9 illustrates a configuration having display lamps for individual optical axes only on the part of the main light detecting device 12 . However, the display lamps 33 may be provided only on the part of the main light emitting device 11 or in both devices 11 12 . Similarly, display lamps 33 for individual optical axes may be provided as the optical axis adjustment display 32 in the sub light detecting device 13 and/or the subs light emitting device 14 .
As one type of one or more above-listed examples, FIG. 10 shows optical axis adjustment displays 30 in form of a liquid crystal display or seven segment LEDs 34 configured to make a numerical representation of the number of optical axes of detected light beams, number of interrupted optical axes or ratio between interrupted optical axes and the other optical axes of detected light beams. FIG. 10 illustrates such numerical displays 34 in both the light emitting and detecting devices 11 , 12 , but only one of the devices 11 12 may have such a numerical display 34 . Similarly, one or both of the sub light detecting and emitting devices 13 , 14 may have such a numerical display 34 .
In FIG. 8, reference numeral 36 denotes a teaching switch whose functions will be explained later. Although the teaching switch 36 is provided on the main light detecting device 12 in the example of FIG. 8, it may alternatively be positioned on the main light emitting device 11 .
Referring to FIG. 11, the main light emitting device 11 includes N (eight, for example) emitter circuits 41 for driving N LEDs 40 used as light emitting elements, an LED switching circuit (optical axis switching circuit) 42 for scanning these light emitting circuits 41 in a time-sharing manner, and an LED control circuit 43 for totally controlling the main light emitting device 11 . The LED control circuit 43 outputs a control signal to the optical axis adjustment display 30 and the output display 31 .
The main light emitting device 11 further includes a first emitter communication control circuit 44 for controlling bi-directional signal exchange of the main light emitting device 11 with the main light detecting device 12 , sub light detecting device 13 , etc., and a second emitter communication control circuit 45 for controlling communication between the main light emitting device 11 and a further main light emitting device (not shown) that may be additionally connected in series thereto for making a larger light curtain.
On the other hand, the main light detecting device 12 has N (eight, for example) detector circuits 51 for driving N photodetectors 50 , a photodetector switching circuit 52 for scanning these light detecting circuits in a time-sharing manner, an amplifier circuit 53 , and a photodetector control circuit 54 for totally controlling the main light detecting device 12 . The photodetector control circuit 54 outputs a control signal to the optical axis adjustment display 30 and the output display 31 .
The main light detecting device 12 further includes a first detector communication control circuit 55 for controlling bi-directional signal exchange of the main light detecting device 12 with the main light emitting device 11 , sub light detecting device 13 , etc., and a second detector communication control circuit 56 for controlling communication between the main light detecting device 12 and a further main light detecting device (not shown) that may be additionally connected in series thereto to make a larger light screen.
Furthermore, the main light detecting device 12 includes a signal processing circuit 57 . The circuit 57 is typically configured to be always fed by the photodetector control circuit 54 with signals indicating whether light beams of respective optical axes have been normally detected by respective photodetectors or not, and to process the signals accordingly. When the signal processing circuit detects from those signals that optical blockage has occurred two or three times within a predetermined period of time, it supplies an OFF signal through the output circuit 58 to an external device (not shown) such as a control panel of the press 20 or an alarm lamp associated with the light curtain made by the main light emitting device 11 and the main light detecting device 12 in order to stop the press 20 immediately.
The sub light detecting device 13 , best shown in FIG. 12, includes two detector circuits 61 for driving two photodetectors 60 , in case of this embodiment, a photodetector switching circuit 62 for scanning these detector circuits in a time-sharing manner, an amplifier circuit 63 , a photodetector control circuit 64 for totally controlling the sub light detecting device 13 , and a sub detector communication control circuit 65 for controlling bi-directional signal exchange of the sub light detecting device 13 with the main light emitting device 11 , sub light emitting device 14 , etc., so that a control signal is output from photodetector control circuit 64 to the optical axis adjustment display 32 .
The sub light emitting device 14 , best shown in FIG. 13, includes N emitter circuits 71 for driving two LEDs 70 used as light emitting elements, an LED switching circuit (optical axis switching circuit) 72 for scanning these emitter circuits 71 in a time-sharing manner, and an LED control circuit 73 for totally controlling the sub light emitting device 14 . The sub light emitting device 14 includes also includes a sub emitter communication control circuit 74 for controlling bi-directional signal exchange of the sub light emitting device 14 with the main light emitting device 12 , sub light detecting device 13 , etc., so that a control signal is output from the LED control circuit to the optical axis adjustment display 32 .
The safeguard system 100 is configured to selectively activate LEDs and photodetectors in associated light emitting and detecting devices at predetermined sequential timings, thereby to prevent the photodetectors from receiving light beams of optical axes other than their own optical axes, by exchanging information among the main light emitting device 11 , main light receiving device 12 , sub light receiving device 13 and sub light detecting device 14 via the signal line or communication line 22 .
The main light emitting device 11 and the main light detecting device 12 is desirably preset to follow a basic operation sequence shown in FIG. 14 . For example, in case the light curtain is formed without using the sub light detecting and emitting devices 13 , 14 , that is, in case a light curtain is made solely by the main light emitting and detecting devices 11 , 12 , the main light emitting and detecting devices 11 , 12 operate according to the preset basic operation sequence of FIG. 14 (basic operation mode). Although FIG. 14 shows the basic operation sequence of the main light emitting device 11 , individual photodetectors of the main light detecting device 12 are activated synchronously with activation of associated individual LEDs of the main light emitting device 11 .
It will be appreciated from FIG. 14 that, in the basic operation sequence of the main light emitting and detecting devices 11 , 12 , the activated duration of time (T 1 ) of each LED is constant for all LEDs and photodetectors, and the pause time from deactivation of each LED or photodetector to activation of the next LED or photodetector (T 2 ) is also constant. That is, respective sets of associated LEDs and photodetectors are sequentially activated periodically for the same duration of time. The basic operation sequence shown in FIG. 14 can be automatically established, taking account of the periods of time T 1 , T 2 and the number of all optical axes between the main light emitting and detecting devices 11 , 12 . An operation program or an electric circuit may realize this operation sequence.
In contrast, FIG. 15 shows an example of a multi-detection or modified operation sequence for use when operations of the sub light detecting device 13 and the sub light emitting device 14 are incorporated. As shown in FIG. 15, just after activating the LED for the third optical axis of the main light emitting device 11 , the modified operation sequence activates the LED for the third optical axis of the sub light detecting device 14 , while deferring activation of subsequent LEDs for subsequent optical axes. After that, the modified operation sequence activates the LED for the fourth optical axis of the main light emitting device 11 and, just after thereof, activates the associated LED of the sub light emitting device 14 , while here again deferring activation of subsequent LEDs for subsequent optical axes.
Instead of the sequence shown in FIG. 15, another sequence is also employable, in which the sub light emitting device 14 starts emission after the main light emitting device 11 completes emission from its all LEDs, and after the sub light emitting device 14 completes emission from its all LEDs, emission from the main light emitting device 11 is resumed (FIG. 16 ).
In the safeguard system 100 , as apparent from the foregoing explanation, full extensions of six optical axes, namely, the first, second and fifth to eighth optical axes, between the main light emitting device 11 and the main light detecting device 12 form the main detection area 15 , sectional extensions of the third and fourth optical axes between the main light emitting device 11 and the sub light detecting device 13 form the first sub detection area 16 , and other sectional extensions of the third and fourth optical axes between the sub light emitting device 14 and the main light detecting device 12 form the second sub detection area 17 . Then, light beams traveling in the main and sub detection areas, 15 , 16 , 17 make a light curtain extending all around the projecting portion 21 .
For example, if an optical obstacle such as a part of the body of personnel blocks the first optical axis in the main detection area 15 formed between the main light emitting device 11 and the main light detecting device 12 as shown in FIG. 17, then the first photodetector of the main light detecting device 12 activated in sync with the first LED of the main light emitting device 11 cannot receive the optical beam. From this fact, it can be immediately acknowledged that optical blockage has occurred. Responsively, an OFF signal is supplied from the output circuit 58 through the signal processing circuit or detection circuit 57 contained in the main light detecting device 12 to an external circuit, and the press 20 is stopped immediately.
In another example shown in FIG. 18, if the optical obstacle blocks the third optical axis in the first sub detection area 16 formed between the main light emitting device 11 and the sub light detecting device 13 , the photodetector in the sub light detecting device 13 activated in sync with the third LED of the main light detecting device 11 cannot receive the optical beam. Responsively, the LED in the sub light emitting device 14 for the third optical axis does not emit light, and the associated photodetector in the main light detecting device 12 cannot receive any light beam at the predetermined timing. From this fact, it can be immediately acknowledged that optical blockage has occurred. Responsively, an OFF signal is supplied from the output circuit 58 via the signal processing circuit or detection circuit 57 contained in the main light detecting device 12 to the external device, and the press 20 is stopped immediately.
In the example of FIG. 18, the information that the sub light detecting device 13 did not receive any light beam from the main light emitting device 11 at a predetermined timing may be directly delivered from the sub light detecting device 13 to the main light detecting device 12 not through the step of non-emission from the sub light emitting device 14 and non detection by the main light detecting device 12 so that a blockage output is issued based on that information through the signal processing circuit or detection circuit 57 and the output circuit 58 contained in the main light detecting device 12 to the external device to stop the press 20 immediately.
In a further example shown in FIG. 19, if the optical obstacle S blocks the third optical axis in the second sub detection area 17 formed between the sub light emitting device 14 and the main light detecting device 12 , the photodetector of the main light detecting device 12 cannot receive the optical beam from the LED in the sub light emitting device 14 associated with the third optical axis. From this fact, it is immediately acknowledged that optical blockage has occurred. Responsively, a blockage signal or OFF signal is output through the signal processing circuit or detection circuit 57 and the output circuit 58 contained in the main light detecting device 12 to the external device, and the press 20 is stopped immediately.
Since the main light emitting device 11 , main light detecting device 12 , sub light detecting device 13 and sub light emitting device 14 are connected altogether by the communication line or signal line 22 , the safeguard system 100 can be readily modified to include the signal processing circuit or detection circuit 57 and the output circuit 58 in the main light emitting device 11 so as to output the blockage signal or OFF signal to the external device from the main light emitting device 11 .
Although the safeguard system 100 heretofore explained is configured to operate according to the operation sequence incorporated in the main light emitting device 11 , for example, the invention is also usable with another type of safeguard system 200 having a controller 38 as an additional separate controller as shown in FIG. 20 . In the safeguard system 200 shown here, the controller 38 substantially controls the light emitting and detecting devices such as the main light emitting device 11 . Thereby, any blockage signal from the main light detecting device 12 or sub light detecting device 13 is input to the controller 38 , and an ON signal or OFF signal is output from the controller 38 toward an external device.
Also in the safeguard system 200 , a modified operation sequence may be generated substantially in the photodetector control circuit 54 of the main light detecting device 12 through procedures explained later in detail. Alternatively, the controller 38 may realize this function of the photodetector control circuit 54 to generate the modified operation sequence.
In the safeguard system 20 , the optical axis adjustment display 30 on one or both of the main light emitting/detecting devices 11 , 12 , and the optical axis adjustment display 32 on one or both of sub light emitting devices 13 , 14 may be replaced by an optical axis adjustment display 39 provided on the controller 38 , or alternatively, a teaching switch 36 may be provided (FIG. 20 ). The optical axis adjustment display 39 may have the same configuration as that of the optical axis adjustment display 30 or 31 already explained, or may be of any type of representation of optical axes among those listed herein before.
Alternatively, the controller 38 may include circuits similar to the signal processing circuit 57 and the output circuit 58 (FIG. 11 ), already explained, to output a blockage signal from the controller 38 to an external device (FIG. 20 ).
FIG. 21 et seq. are diagrams related to installation of the safeguard system 100 or 200 . Explanation is made below with reference to these figures about procedures for installing the light emitting and detecting devices and automatic generation of a multi-detection sequence or modified sequence triggered by ON manipulation of the teaching switch 36 .
First Step: Setting and Positioning of the Main Light Emitting and Detecting Devices 11 and 12 (FIG. 22)
The main light emitting device 11 and the main light detecting device 12 are first placed in predetermined positions relative to the press 20 , for example, from which the projecting portion 21 has been removed.
After that, relative positions of the main light emitting and detecting devices 11 , 12 are adjusted precisely (FIG. 22 ). That is, optical axes between the main light emitting and detecting devices 11 , 12 are adjusted. This optical axis adjustment is carried out by fine adjustment of positions of the main light emitting and/or detecting devices 11 , 12 so that all of their optical axes coincide. The operator can confirm whether the main light detecting device 12 has detected all optical beams sequentially emitted from LEDs of the main light emitting device 11 are certainly detected, that is, whether the main light emitting and detecting devices 11 12 have been precisely positioned relative to each other, by watching the optical axis adjustment displays or display lamps 30 on the main light emitting and detecting devices 11 , 12 , or the optical axis adjustment display on the controller 38 .
Second Step: Mounting of the Projecting Portion 21 (FIG. 23)
After completion of the first step, the projecting portion is mounted to the press 20 . As a result, some of the optical axes between the main light emitting and detecting devices 11 , 12 are interrupted.
Third Step: Generation of the Multi-detection Operation Mode (FIG. 21)
The operator or user next turns ON the teaching switch 36 (step S 1 of FIG. 21 ). As a result, the safeguard system 100 or 200 enters in the teaching mode for automatically generating the multi-detection or modified operation sequence that determines emitting/detecting operations not only of the main light emitting and detecting devices 11 , 12 but also of the sub light detecting and emitting devices 13 , 14 in the multi-detection mode. The ON signal from the teaching switch 36 is input into the photodetector control circuit 54 .
Once the system enters in the teaching mode, the photodetector control circuit 54 having acknowledged the teaching mode transfers the information to the LED control circuit 43 through the communication line or signal line 22 , and the main light emitting device 11 starts emission according to the basic operation sequence shown in FIG. 14 (step S 2 of FIG. 21 ).
When all LEDs of the main light emitting device 11 complete emission of light, the photo detector control circuit 54 recognizes that the third and fourth optical axis, in case of the example shown in FIG. 7, are interrupted by the projecting portion 21 . Responsively, in case of generating the multi-detection operation sequence or modified operation sequence, the photodetector control circuit 54 makes a first blank (a length of time totaling the time T 1 and the time T 2 ) necessary for activation of one of LEDs of the sub light emitting device 14 for the third optical axis (illustrated as the optical axis No. 3 ′ in FIG. 15) after the activation timing of one of LEDs of the main light emitting device 11 for the third axis (illustrated as the optical axis No. 3 in FIG. 15) while delaying activation timings of LEDs for subsequent optical axes. Additionally, the photodetector control circuit 54 makes a second blank (a length of time totaling the time T 1 and the time T 2 ) necessary for activation of the other LED of the sub light emitting device 14 for the fourth optical axis (illustrated as the optical axis No. 4 ′ in FIG. 15) after the activation timing of one of LEDs of the main light emitting device 11 for the fourth axis (illustrated as the optical axis No. 4 in FIG. 15) while delaying emission timings of LEDs for subsequent optical axes. Furthermore, the photodetector control circuit 54 incorporates timings for activation of the sub light emitting device 14 in the first and second blanks. In this manner, the photodetector control circuit 54 automatically generates the modified operation sequence shown in FIG. 15 for activating the sub light emitting device 14 as well at the timings corresponding to the first and second blanks. Hereinbelow, optical axes interrupted by the projecting portion 21 are called planking optical axis.
Alternatively, if the multi-detection operation sequence or modified operation sequence of FIG. 16 should be generated, the photodetector control circuit 54 may make the first and second blanks necessary for activation of LEDs of the sub light emitting device 14 between activation timings of LEDs of the main light emitting device 11 for the eighth and first optical paths, and may automatically generate the sequence for activating the sub light emitting device 14 at the timings corresponding to the first and second blanks.
As a result, the multi-detection operation sequence or modified operation sequence as shown in FIG. 15 or 16 is automatically generated (step S 4 of FIG. 21 ), and the teaching mode ends (step S 5 of FIG. 21 ).
In the process explained above, the photodetector control circuit 54 that can be regarded as CPU of the main light emitting device 12 recognizes the ON state of the teaching switch 36 , and the photodetector control circuit 54 automatically generates the modified operation sequence (FIG. 15 or 16 ) in response to detection of interruption of particular optical axes. However, this function may be given to the photodetector control circuit 43 of the main light emitting device 11 so that the modified operation sequence is established on the part of the main light emitting device 11 . Alternatively, it is of course possible that the main light emitting device 11 and the main light detecting device 12 share the function of automatically generating the modified operation sequence.
Fourth Step: Setting and Positioning of the Sub Light Detecting Device 13 (FIG. 24)
The sub light detecting device 13 is placed adjacent to one side of the projecting portion in an opposed relationship with the main light emitting device 11 . For accurate positioning of the sub light detecting device 13 relative to the main light emitting device 11 , it will be necessary to move the sub light detecting device 13 vertically or change its orientation such that optical axes coincide between the sub light detecting device 13 and the main light emitting device 11 .
Since the modified operation sequence is already established in the third step 3 such that the sub light detecting device 13 is activated at given timings for detecting light beams only of the third and fourth optical axes, in case of the example of FIG. 7, from the main light emitting device, the operator can accomplish positioning of the sub light detecting device 13 relative to the main light emitting device 11 by moving the former while confirming the degree of adjustment through the optical axis adjustment display or display lamp 32 on the sub light detecting device 13 or the optical axis adjustment display 39 .
Fifth Step: Setting and Positioning of the Sub Light Emitting Device 14 (FIG. 25)
The sub light emitting device 14 is next placed adjacent to the opposite side of the projecting portion 21 in an opposed relationship with the main light detecting device 12 . Here again, for accurate positioning of the sub light emitting device 14 relative to the main light detecting device 12 , it will be necessary to slightly move the sub light emitting device 14 vertically or change its orientation such that, in case of the example of FIG. 7, light beams emitted from the sub light emitting device 14 are detected by photodetectors of the main light detecting device for the third and fourth optical axes. The operator can proceed with this adjustment while confirming the degree of adjustment through the optical axis adjustment display on the sub light emitting device 14 or the optical axis adjustment display 39 on the controller 38 . Thus the adjustment of optical axes between the sub light emitting device 14 and the main light detecting device 12 is accomplished.
Sixth Step: Confirmation of Detection of the Minimum Object (FIG. 26)
Next confirmed is whether the system 100 or 200 can detect a certain minimum object in any of the detection areas defined by the main light emitting and detecting devices 11 , 12 and the sub light detecting and emitting devices 13 , 14 . The operator can carry out this confirmation by moving a minimum object (not shown) to be detected along the route shown by arrows in FIG. 26 and confirming that a blockage signal is output from the system 100 or 200 when the object intrudes into the detection areas.
For the positioning of the sub light detecting device 13 in the fourth step, it is convenient to removably attach a spacer SP on the top and/or bottom of the sub light detecting device 13 as shown in FIG. 27 . The spacer SP may be a plate member, for example, which does not interrupt light beams of adjacent optical axes (in the example of FIG. 7, second and fifth optical axes) when the sub light detecting device 13 is accurately positioned, but does interrupt the adjacent light beams when the sub light detecting device 13 is offset vertically, even if slightly.
In another example, the spacer SP may be a plate having a small through hole, not shown. The operator can accurately position the sub light detecting device 13 by finding its position where the light beam of the second or fifth optical axis passes through the hole of the plate. In other words, when the sub light detecting device is offset vertically or in the front and back direction, even if slightly, the light beam of the second or fifth optical axis will be interrupted by the spacer SP having the through hole.
For the above-explained adjustment of optical axes of the light emitting and detecting devices provided in the safeguard system 100 or 200 , the projecting portion 21 is removed from the press 20 in the process of adjusting the optical axes of the main light emitting and detecting devices 11 , 12 . However, as shown in FIG. 28, relative accurate positioning between the main light emitting and detecting devices 11 , 12 , namely, adjustment of their optical axes, may be carried out under the existence of the projecting portion 21 on the press 20 .
In this case, adjustment of optical axes is carried out by positioning the main light emitting and detecting devices 11 , 12 to ensure that all light beams other than those of the optical axes interrupted by the projecting portion 21 (the third and fourth optical axes in the foregoing example) enter into the main light detecting device 12 . The operator will confirm through the optical axis adjustment displays or display lamps 30 on the main light emitting device 11 and the main light detecting device 12 or the optical axis adjustment display 39 on the controller 38 whether the adjustment of optical axes has been accomplished or not. However, for easier confirmation, it is advantageous to provide a switch SW shown in FIG. 28 on the main light detecting device 12 , main light emitting device 11 and/or controller 38 such that the operator can confirm the intensities of detected light of individual optical axes through the optical axis adjustment display 30 or 39 by manipulating the switch SW. The optical axis display device 30 may be of the type having display lamps 33 exclusive for individual optical axes (FIG. 28 ), or in form of the numerical display 34 using a liquid crystal or seven segments of LEDs as shown in FIG. 10 . The numerical display 34 may have some different display modes for selectively representing the number of optical axes of detected light beams, number of interrupted optical axes, position of an interrupted optical axis, and so on, such that, for example, the position of the optical axis currently interrupted on the numerical display 34 under the operator's choice to confirm whether positioning of the main light emitting and detecting devices 11 , 12 has been accomplished or not.
Although the modified example of optical axis adjustment has been roughly explained with reference to FIG. 28, its procedures and automatic generation of the multi-detection sequence or modified operation sequence responsive to the instruction through the teaching switch 36 will follow the following steps.
First Step: Setting and Positioning of the Main Light Emitting and Detecting Devices 11 , 12 Relative to the Press 20 Having the Protecting Portion 21 (FIG. 28)
The main light emitting device 11 and the main light detecting device 12 are accurately positioned relative to each other (See FIG. 22 ). More specifically, the main light emitting and detecting devices 11 , 12 are placed at spaced-apart positions from the projecting portion 21 of the press 20 at opposite sides thereof, and their optical axes are adjusted accurately. This adjustment of optical axes is achieved by fine adjustment of the main light emitting and detecting devices 11 , 12 so as to accurately align their optical axes. The operator can confirm whether the main light detecting device 12 has detected all optical beams sequentially emitted from LEDs of the main light emitting device 11 are certainly detected, that is, whether the main light emitting and detecting devices 11 12 have been precisely positioned relative to each other, by watching the optical axis adjustment displays or display lamps 30 on the main light emitting and detecting devices 11 , 12 , or the optical axis adjustment display on the controller 38 .
Second Step: Generation of the Multi-detection Operation Sequence (FIG. 21)
The operator or user next turns ON the teaching switch 36 (step S 1 of FIG. 21 ). As a result, the safeguard system 100 or 200 enters in the teaching mode for automatically generating the multi-detection or modified operation sequence that determines emitting/detecting operations not only of the main light emitting and detecting devices 11 , 12 but also of the sub light detecting and emitting devices 13 , 14 in the multi-detection mode. The ON signal from the teaching switch 36 is input into the photodetector control circuit 54 .
Once the system enters in the teaching mode, as already explained, the photodetector control circuit 54 having acknowledged the teaching mode transfers the information to the LED control circuit 43 through the communication line or signal line 22 , and the main light emitting device 11 starts emission according to the basic operation sequence shown in FIG. 14 (step S 2 of FIG. 21 ).
When all LEDs of the main light emitting device 11 complete emission of light, the photo detector control circuit 54 recognizes that the third and fourth optical axis, in case of the example shown in FIG. 7, are interrupted by the projecting portion 21 . Responsively, assuming here again that the multi-detection operation sequence should be generated, the photodetector control circuit 54 makes a first necessary for activation of one of LEDs of the sub light emitting device 14 for the third optical) after the activation timing of one of LEDs of the main light emitting device 11 for the third axis while delaying activation timings of LEDs for subsequent optical axes. Additionally, the photodetector control circuit 54 makes a second blank necessary for activation of the other LED of the sub light emitting device 14 for the fourth optical axis after the activation timing of one of LEDs of the main light emitting device 11 for the fourth axis while delaying emission timings of LEDs for subsequent optical axes. Furthermore, the photodetector control circuit 54 incorporates timings for activation of the sub light emitting device 14 in the first and second blanks. In this manner, the photodetector control circuit 54 automatically generates the modified operation sequence shown in FIG. 15 for activating the sub light emitting device 14 as well at the timings corresponding to the first and second blanks. Hereinbelow, optical axes interrupted by the projecting portion 21 are called planking optical axis. Also when the multi-detection operation sequence of FIG. 16 should be made, its procedures are the same as those already explained.
As a result, as already explained, the multi-detection operation sequence or modified operation sequence as shown in FIG. 15 or 16 is automatically generated (step S 4 of FIG. 21 ), and the teaching mode ends (step S 5 of FIG. 21 ).
Third Step: Setting and Positioning of the Sub Light Detecting Device 13 (FIG. 24 )
In the same manner as the embodiment already explained, the sub light detecting device 13 is placed adjacent to one side of the projecting portion in an opposed relationship with the main light emitting device 11 . For accurate positioning of the sub light detecting device 13 relative to the main light emitting device 11 , it will be necessary to move the sub light detecting device 13 vertically or change its orientation such that optical axes coincide between the sub light detecting device 13 and the main light emitting device 11 .
Since the modified operation sequence is already established in the third step 3 such that the sub light detecting device 13 is activated at given timings for detecting light beams only of the third and fourth optical axes, in case of the example of FIG. 7, from the main light emitting device, the operator can accomplish positioning of the sub light detecting device 13 relative to the main light emitting device 11 by moving the former while confirming the degree of adjustment through the optical axis adjustment display or display lamp 32 on the sub light detecting device 13 or the optical axis adjustment display 39 .
Fourth Step: Setting and Positioning of the Sub Light Emitting Device 14 (FIG. 25)
In the same manner as the embodiment already explained with reference to FIG. 25, the sub light emitting device 14 is next placed adjacent to the opposite side of the projecting portion 21 in an opposed relationship with the main light detecting device 12 . Here again, for accurate positioning of the sub light emitting device 14 relative to the main light detecting device 12 , it will be necessary to slightly move the sub light emitting device 14 vertically or change its orientation such that, in case of the example of FIG. 7, light beams emitted from the sub light emitting device 14 are detected by photodetectors of the main light detecting device for the third and fourth optical axes. The operator can proceed with this adjustment while confirming the degree of adjustment through the optical axis adjustment display on the sub light emitting device 14 or the optical axis adjustment display 39 on the controller 38 . Thus the adjustment of optical axes between the sub light emitting device 14 and the main light detecting device 12 is accomplished.
Fifth Step: Confirmation of Detection of the Minimum Object (FIG. 26)
In the same manner as already explained with reference to FIG. 26, next confirmed is whether the system 100 or 200 can detect a certain minimum object in any of the detection areas defined by the main light emitting and detecting devices 11 , 12 and the sub light detecting and emitting devices 13 , 14 . The operator can carry out this confirmation by moving a minimum object (not shown) to be detected along the route shown by arrows in FIG. 26 and confirming that a blockage signal is output from the system 100 or 200 when the object intrudes into the detection areas.
In the foregoing explanation, optical axes interrupted by the projecting portion 21 are identified in the positioning step of the main light emitting and detecting devices 11 , 12 . If, however, the operator can identify the interrupted axes, i.e. the blanking optical axes beforehand, the operator may supply the information to the system 100 or 200 through an external means. Similarly, the multi-detection operation sequence or modified operation sequence (FIG. 15) may be generated outside the system 100 or 200 , and this information may be supplied together with the information about the blanking optical axes to the system 100 or 200 through a communication means using infrared rays or electric waves, USB, Ethernet, or the like. Any skilled person in the art will readily understand that the operator can easily generate the multi-detection sequence or modified operational sequence (FIG. 15) by using a personal computer, for example, and inputting ID numbers of the blanking axes to the computer.
Once the positioning (optical axis adjustment) of the light emitting and detecting devices is accomplished, the safeguard system 100 or 200 behaves according to the modified operation sequence shown in FIG. 15 or 16 to sequentially emit and detect light from the first optical axis to the eighth optical axis, and repeats this cycle of optical scan again from the first optical axis. In each cycle of the operation, the sub light detecting device 13 is activated in sync with activation of the third and fourth optical axes of the main light emitting device 11 thereby to selectively change each corresponding photodetector thereof active. Each photodetector of the main light detecting device 12 is selectively activated in sync with operations of the main light emitting device 11 and the sub light emitting devices 14 . As a result, as to the third and fourth optical axes, the sub light detecting device 13 detects light beams from the main light emitting device 11 , and the main light detecting device 12 detects light beams from the sub light emitting device 14 .
That is, in the sub light detecting device 13 , photodetectors are selectively activated in synch with activation of LEDs of the corresponding third and fourth optical axis of the main light emitting device 11 according to the modified operation sequence (FIG. 15 or 16 ). When each photodetector of the sub light detecting device 13 detects light beam from the main light emitting device 11 , the sub light detecting device 13 supplies an emission command to the sub light emitting device 14 directly or via the controller 38 .
When the sub light emitting device 14 receives the information from the sub light detecting device 13 or controller 38 according to the modified operation sequence (FIG. 15 or 16 ) automatically generated by the initial setting, one of LEDs of the sub light emitting device 14 for the corresponding optical axis is changed active. The sub light emitting device 14 may be controlled otherwise such that it emits a light beam exclusively following to the modified sequence of FIG. 15 or 16 without the emission command from the sub light detecting device 13 or controller 38 , or it emits a light beam exclusively following to the emission command from the sub light detecting device 13 or controller 38 .
Although some embodiments of the invention have been explained taking examples in witch the safeguard system 100 or 200 includes a set of main light emitting and detecting devices 11 , 12 , one sub light detecting device 13 and one sub light emitting device 14 , the safe guard system 100 or 200 may include two or more sets of sub light detecting and emitting devices 13 , 14 , and in addition to that, the system 100 or 200 may include two or more sets of main light emitting and detecting devices 11 , 12 that are connected by a communication line or signal line to make a wider light curtain.
Although some embodiments have been explained as providing the optical adjustment displays or display lamps 30 on both the main light emitting and detecting devices 11 , 12 , they may be modified to provide the optical axis adjustment display or display lamp 30 on one of the main light emitting and detecting devices.
Also regarding the sub light detecting and emitting devices 13 , 14 , the optical axis adjustment display or display lamp 32 may be provided on only of the sub light detecting and emitting devices 13 , 14 . In this case, the optical axis adjustment display or display lamp 32 is preferably provided on the sub light detecting device 13 . Optical axis adjustment of the sub light detecting and emitting devices 13 , 14 may be confirmed through the optical axis adjustment display 39 of the controller 38 .
Furthermore, while the system 100 or 200 actually works after installation and optical axis adjustment of the light emitting and detecting devices 11 through 14 according the method explained heretofore, if the light emitting and detecting devices 11 to 14 again need optical axis adjustment as the maintenance of the system 100 or 200 , the operator may proceed with substantially the same procedures as explained above. In this case, the operator may first adjust optical axes between the main light emitting and detecting devices, or may first adjust optical axes between the sub light detecting and emitting devices prior to adjustment of the main light emitting and detecting devices. | A method of installing a multi-beam photoelectric safeguard system for making a light curtain of closely aligned light beams closely to a pressing machine first positions main light emitting and detecting devices ( 11, 12 ). The method next mounts a projecting portion ( 21 ) to the pressing machine and identifies optical axes interrupted by the projecting portion ( 21 ). Subsequently, after setting a sub light detecting device ( 13 ) adjacent to one side of the projecting portion ( 21 ), the method adjusts optical axes between the sub light detecting device ( 13 ) and the main light emitting device ( 11 ). Finally, after setting a sub light emitting device ( 14 ) adjacent to the other side of the projecting portion ( 21 ), the methods adjusts optical axes between the sub light emitting device ( 14 ) and the main light detecting device ( 12 ). | 5 |
BACKGROUND OF THE INVENTION
This invention relates generally to propellant compositions and more particularly to solventless double base propellants having an energetic plasticizer with no secondary nitroxy groups.
Double base propellants are homogenous propellants having a binder e.g. nitrocellulose and an energetic plasticizer. The use of these propellants in gun, missile or gas generating auxiliary equipment is known in the art. This type of propellant has many advantages over single base propellants. For example, single base propellants have a greater variance in performance. This is due to their having been manufactured by a solvent process and retaining a varying amount of residual volatile solvent. A solvent process is needed to manufacture a single base propellant. As the amount of solvent is increased, an objectionably long drying cycle becomes required by the solvent process, and the amount of retained residual solvent also increases. However the adoption of solventless double base propellants for gun and auxiliary equipment uses has been slight due mainly to a lack of an alternative energetic plasticizer to nitroglycerin.
Although nitroglycerin is extremely energetic and has a good plasticizing capacity, the many disadvantages of this nitrate ester discourages its use. First of all, nitroglycerin is extremely hazardous. The sensitivity and high energy make nitroglycerin dangerous to handle and makes the resulting propellant composition more sensitive to unwanted detonation. Also nitroglycerin is volatile and the resulting vapors cause sickness and headaches to humans, thereby causing health problems in the manufacture, handling, and storage of any composition containing nitroglycerin.
The sensitivity of nitroglycerin also causes the propellant composition to have a high hazard classification which means extra expense for storage, and a more limited reserve. Another disadvantage is exudation. Nitroglycerin has a tendency to migrate out of the composition, and thereby result in poorer firing accuracy due to variance in propellant strength.
Flame temperatures of a propellant containing nitroglycerin are high. This characteristic necessitates the addition of coolants which produce soot and smoke in the exhaust. If coolants are not used, the high burning temperature excessively erodes the barrel in comparison with single-base powders.
In applications requiring a high degree of mechanical strength e.g. most missile and many gun propellant uses, the solvent process is used to make the double base propellants. However, difficulties are encountered in the process itself and in the end product. The solvent process requires a lengthy drying cycle and a final blending. During the solvent process, volatiles are introduced into the propellant composition. Volatiles shorten the shelf life of a propellant. With nitroglycerin propellants, a serious problem is compounded in that compositions containing nitroglycerin have already a poor shelf life as compared to single base propellants.
Since the beginning of World War II much effort has been expended to find an alternative plasticizer to nitroglycerin and a way of avoiding the necessity of a solvent manufacturing process for most gun propellants. Unfortunately the resulting compositions had poor performance or poor mechanical strength or had to rely excessively on solvents in order to process the propellant.
Nitrate esters like polyolpolynitrates have excellent energy content. But upon contact with ordinary nitrocellulose, only the outer layers of the nitrocellulose softened. No plasticizing of the nitrocellulose takes place, which is essential for any propellant composition. Other nitrate esters are good plasticizers but have low energy and have many of the drawbacks of nitroglycerin, such as poor stability, high sensitivity, as well as being hazardous to the health of humans.
Some attempts have been made to combine various nitrate esters together or with nitroglycerin. These attempts resulted in a propellant with low energy levels or poor mechanical strength. The method of preparation required the use of solvents or of an expensive preprocessed nitrocellulose or other binder. Since the preprocessing involved solvents, the resulting propellant had many of the drawbacks of a propellant prepared by a solvent process.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to provide a double base propellant prepared by a solventless process having superior strength and performance.
Another object of this invention is to provide a superior double base propellant containing no nitroglycerin.
Still another object of this invention is to provide a double base propellant having a long shelf life.
A further object of this invention is to provide a double base propellant with improved stability.
Another object of this invention is to provide a double base propellant with improved performance consistency.
Another object of this invention is to provide a double base propellant having lower flame temperature.
Also an object of this invention is to provide a double base gun propellant which can be formulated with a wide range of mass impetus and particularly with a mass impetus above that of the nitrocellulose-nitroglycerin propellants.
Also another object of this invention is to provide a double base propellant with reduced flash and visible flame.
Still another object of this invention is to provide a double base propellant having a low and controlled level of volatiles, which are not organic in nature.
And another object of this invention is to provide a double base propellant having a plasticizer which does not migrate.
Yet another object of this invention is to provide a double base propellant causing fewer health hazards in its preparation, handling and storage.
These and other objects are attained by increasing the plasticizing proficiency of metriol trinitrate through the addition of triethylene glycol dinitrate to such a degree that any grade of nitrocellulose or similar binder may form a double base propellant with metriol nitrate without the use of solvents in the preparation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Double base propellants include a binder and an energetic plasticizer. This basic composition is usually supplemented with a number of additives. The use of a mixture of metriol trinitrate and triethylene glycol dinitrate as an energetic plasticizer does not restrict the choice of these other art recognized ingregients.
While preferably the nitrocellulose used herein is a water wet soluble grade (12.6%N), other types of nitrocellulose with a nitrogen content as low as 12.0% N or as high as 13.5%N may be used. The nitrocellulose may constitute from about 30 to about 70 weight percent of the total composition. Preferably the nitrocellulose would constitute from about 40 to about 60 weight percent with the most preferred range being from about 45 to about 50 weight percent.
Examples of suitable stabilizers which may be used are 2-nitrodiphenylamine (2NDPA), ethyl centralite (EC), and N-methyl paranitroanilines. The preferred stabilizer is ethyl centralite. The stabilizer may constitute from about 0.5 to about 5 weight percent of the total composition weight with about 1 to about 4 weight percent preferred and about 1 to about 2 weight percent the most preferred.
If it is desired to use a nonenergetic plasticizer in addition to the energetic one, such art recognized plasticizers as di-n-propyl adipate, triacetin, di-isobutyl azelate, metriol triacetate, and dibutylphthylate, mixtures thereof, and the like may be used. Usually the amount would be between about 0.5 to about 9.0 weight percent.
A flash pressant may be added such as crylolite in an amount from 0.5 to 3 weight percent.
If a particular formulation is causing a coppering problem, a lead salt, e.g. lead β-resorcylate may be added as a decoppering agent.
Other additives which may advantageously be incorporated in a propellant formulation encompassed by the present invention include candelilla wax which in minute quantities facilitates extrusion.
The new plasticizer of this invention for solventless double base propellants is a mixture of metriol trinitrate (MTN) in an amount from about 30 to about 60 weight percent with about 25 to about 50 weight percent preferred and from about 39 to about 42 weight percent the most preferred, and triethylene glycol dinitrate (TEGDN) in an amount from about 2 to about 20 weight percent with about 3 to about 11 weight percent preferred and two ranges of from about 3 to about 4 and from about 9 to about 11 weight percent the most preferred.
Increasing the amount of MTN relative to TEGDN diminishes the plasticization of nitrocellulose, increases the energy content of the propellant composition, increases the flame temperature, and diminishes the flash. The most preferred ratios of MTN to TEGDN are 13:1 and about 4:1. The 13:1 ratio gives a propellant with a high energy content and a flame temperature comparable to single base propellants of similar energy content if a non energetic plasticizer is included. It should be noted that the non-energetic plasticizer is added more to minimize the flame temperature than to increase the plasticization of nitrocellulose. The MTN/TEGDN energetic plasticizer is capable of plasticizing nitrocellulose up to a ratio of 15:1.
One of the major advantages of this invention is that it may be prepared by almost any process and particularly a propellant of exceptional strength can be obtained from the solventless process. Accordingly the solventless process is the preferred method of preparation. A basic solventless method of preparation would include the following steps. The nitrocellulose is mixed to a thin slurry in about 10 times its weight of warm water. A solution of the desired additives is admixed with the slurry. A solution of metriol trinitrate and triethylene glycol dinitrate is slowly added to the slurry. Thereafter, the slurry is filtered or centrifuged to remove most of the water and the resulting paste is aged for a period of 1 to 5 days or more at a temperature of about 130° F. At this point it has a moisture level of from 8 to 15 percent and the mixture is milled to a homogenous colloid on a heated differential rolling mill, followed by a heated even speed mill. The method of mixing is not critical, provided that distribution of all ingredients is uniform and no losses of ingredients occur which are not otherwise accounted for. The sheet propellant formed may be extruded into any desired form.
The general nature of the invention having been set forth, the following examples are presented as specific illustrations thereof. It is understood that the invention is not limited to these examples but is susceptible to different modifications that would be recognized by one of ordinary skill in the art.
TABLE I______________________________________Ingredient Ex. 1 Ex. 2 Ex. 3______________________________________Nitrocellulose (12.6%) 46.0 34.9 53.0metriol trinitrate 38.5 46.0 41.9triethylene glycol dinitrate 3.0 15.0 4.0ethyl centralite 2.0 1.0 1.0basic lead carbonate 1.0 -- --potassium sulfate 1.0 1.0 --dibutyl phthalate 8.4 -- --polyethylene -- 2.0 --candelilla wax 0.1 0.1 0.1______________________________________
The above examples were tested for a number of physical and thermodynamic properties and the results are summarized in the next table.
TABLE 2______________________________________Test Ex. 1 Ex. 2 Ex. 3______________________________________Impetus, in-lb/lb 3.56 4.3 4.4 × 10.sup.6 × 10.sup.6 × 10.sup.6Flame Temp., ° K 2260 2790 3130Moles of Gas/100 gun of prop 4.76 4.61 4.25Heat of Explosion, cal/gm 750 800 998______________________________________
Several sample formulations were made with different explosive plasticizer ratios or a new inert plasticizer. These compositions are given in TABLE 3. Again these samples were prepared by the solventless method described previously. After the manufacture of the rolled sheet stock, each composition was extruded through a 0.250 - inch - diameter die as a solid rod. These rods were then used for testing.
The method used for performing tensile property was the one developed by Picatinny Arsenal. The strands were cut to a length of 6 inches. Next the ends were potted with mixture of 65% Epon 828 and 75% Versamid 125 to create handles for use in pulling the strands. Table 4 contain the results of the tensile tests.
TABLE 3______________________________________Composition (%) Ex. 1 Ex. 4 Ex. 5 Ex. 6______________________________________Nitrocellulose 46.0 46.0 46.0 46.5(12.0% N)Metriol trinitrate 38.5 38.5 38.5 30.0Triethylene glycol 3.0 3.0 3.0 15.0dinitrateEthyl centralite 2.0 2.0 2.0 2.0Potassium sulfate 1.0 1.0 1.0 1.0Basic lead carbonate 1.0 1.0 1.0 1.0Dibutyl phthalate 8.4 -- -- --Di-isobutyl azelate -- 8.4 -- --Di-normal-propyl -- -- 8.4 4.4adipateCandelilla wax 0.1 0.1 0.1 0.1Total 100.0 100.0 100.0 100.0______________________________________
TABLE 4______________________________________Test temperature77° F 40° F Tensile strength Elong- Tensile strength Elong-Compo- at failure ation at failure ationsition (psi) (%) (psi) %)______________________________________Ex 1 905 20.0 8120 7.8Ex 4 810 19.0 7250 6.6Ex 5 687 21.9 5210 5.0Ex 6 592 22.0 7610 7.4______________________________________
A gun propellant in wide use in this country and in the western world comprises 91 weight percent of nitrocellulose (12.0%N), 1 weight percent of ethyl centralite, 3 weight percent of butyl stearate, 1 weight percent of basic lead carbonate, 1 weight percent of potassium sulfate and 3 weight percent of total volatiles. In the Navy it is referred to as NACO. This particular formulation provides a gun propellant which is cool, clean burning, and not needing soot-producing coolants. The following table shows a comparison of NACO with example composition 1.
TABLE 5______________________________________ NACO Ex 1______________________________________Flame temperature, T.sub.v 2200° K 2260° KHOE (cal/g) 752 750Impetus (in-lb/lb) 3.2 × 10.sup.6 3.56 × 10.sup.6RQ (NACO is reference) 100 98RF (NACO is reference) 100 106Density (lb/in.sup.3) 0.057 0.054Moles gas/100g 4.32 4.76Initial velocity 10.9 5.5variability (ft/sec)Dispersion at 0.59 0.4818,000 yards (%)______________________________________
From these tables it can be seen that a propellant system and process have been developed which can produce high quality propellants for a wide range of force levels. It is of particular interest that more uniform initial velocities are obtained. Further these propellants are prepared by a process requiring no lengthy drying cycle and no final blending normally associated with the manufacture of double base propellants.
Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | Solventless double base propellants plasticized by metriol trinitrate thrh the addition of triethylene glycol dinitrate in a ratio of at least 1:14 triethylene glycol dinitrate to metriol trinitrate. | 2 |
RELATED APPLICATIONS
This application claims priority to PCT Patent Application Serial No. PCT/US2006/32411 filed 17 Aug. 2006 (Aug. 17, 2006 or Jun. 6, 2006), which claim priority to U.S. Provisional Application Ser. No. 60/708,990 filed 17 Aug. 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system and method for monitoring industrial plant activity and to a system and method for using the monitoring data to stabilize plant and industrial productivity, to maximize plant and overall industrial productivity, to track and evaluate plant and industrial productivity, and/or to develop global data dissemination methodologies and/or to develop global industrial responses to natural or man-made industry disruptions.
More particularly, the present invention relates to a system and method for monitoring industrial plant activity, where the method includes imaging plant stacks and/or effluent plumes and relating data derived from the images to an index of plant activity. This invention also relates to a system and method for using the monitoring data to stabilize plant and industrial productivity, to maximize plant and overall industrial productivity, to track and evaluate plant and industrial productivity, and/or to develop global data dissemination methodologies and/or to develop global industrial responses to natural or man-made industry disruptions, where the method includes packaging the plant activity data so that industrial participants and governmental regulatory agencies can change plant and/or industrial output and productivity to adjust, stabilize and/or maximize output of desired industries.
2. Description of the Related Art
Camera and other detection system designed to image plant effluents and thermal emissions have been used for many years to analyze thermal output and effluent compositions for environmental, operational and emission control. Many of these systems are designed to determine effluent plume composition and effluent plume disbursement. However, such systems have not been used to monitor plant output, down time, cycle time, disruptions, etc. in a real time or near real time so that industry and government can better manage overall output and maintain adequate levels of goods and services and so governments, brokers and analysts can be forecast demand and supply economics.
Thus, there is a need in the art for a system and method for monitoring stack and/or effluent plumes and relating data derived therefrom to a measure of plant productivity and industry productivity and packaging the plant and industry productivity data into a format for instantaneous, periodic or intermittent distribution to broker, analyst, industrial and governmental organizations.
SUMMARY OF THE INVENTION
Systems
The present invention provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility and/or a unit and/or units thereof to obtain, produce, store and transmit image data. The system also includes (2) an analysis subsystem for converting the image data into plant output activity data or capacity utilization data.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image data. The system also includes (2) a data processing subsystem capable of correcting the image data for existing environmental factors. The system also includes (3) an analysis subsystem for converting the corrected image data into plant output activity or capacity utilization data.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image data. The system also includes (2) an analysis subsystem for converting the image data into plant output activity or capacity utilization data. The system also includes (3) an accumulation subsystem adapted to accumulate the plant output activity or capacity utilization data.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image data. The system also includes (2) an analysis subsystem for converting the image data into plant output activity or capacity utilization data. The system also includes (3) an accumulation subsystem adapted to accumulate the plant output activity or capacity utilization. The system also includes (4) a trend subsystem adapted to determine trends in plant activity or capacity utilization data.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image output activity or capacity utilization data. The system also includes (2) a data processing subsystem capable of correcting the image output data for existing environmental factors. The system also includes (3) an analysis subsystem for converting the corrected image data into plant output activity or capacity utilization data. The system also includes (4) an accumulation subsystem adapted to accumulate the plant output activity or capacity utilization data. The system also includes (5) a trend subsystem adapted to determine trends in plant activity or capacity utilization data.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image output activity or capacity utilization data. The system also includes (2) an analysis subsystem for converting the image data into plant output activity or capacity utilization data. The system also includes (3) an accumulation subsystem adapted to accumulate the plant output activity or capacity utilization data. The system also includes (4) a trend subsystem adapted to determine trends in plant output activity or capacity utilization data. The system also includes (5) a report subsystem designed to report plant and/or industry output capacity, capacity utilization, and overall plant or industrial trends to end users.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image output activity or capacity utilization data. The system also includes (2) a data processing subsystem capable of correcting the image output activity or capacity utilization data for existing environmental factors. The system also includes (3) an analysis subsystem for converting the corrected image output data into plant output capacity data. The system also includes (4) an accumulation subsystem adapted to accumulate the plant output capacity data. The system also includes (5) a trend subsystem adapted to determine trends in plant output data and a report subsystem designed to produce an industry survey of industrial capacity, maximum output, and/or output trends.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image output data. The system also includes (2) an analysis subsystem for converting the image data into plant output capacity data. The system also includes (3) an accumulation subsystem adapted to accumulate the plant output capacity data, a trend subsystem adapted to determine trends in plant output data. The system also includes (4) a report subsystem designed to produce an industry survey of industrial capacity data. maximum output, and output trends. The system also includes (5) an adjustment subsystem designed to adjust individual facility output to adjust and/or maximize overall all industrial output.
The present invention also provides a system for monitoring and determining plant output activity or capacity utilization including (1) an imaging subsystem capable of imaging stacks of and/or effluent plumes generated by an industrial facility or units thereof to obtain, produce, store and transmit image output data. The system also includes (2) a data processing subsystem capable of correcting the image output data for existing environmental factors. The system also includes (3) an analysis subsystem for converting the corrected image data into plant output capacity data. The system also includes (4) an accumulation subsystem adapted to accumulate the plant output capacity data. The system also includes (5) a trend subsystem adapted to determine trends in plant output data. The system also includes (6) a report subsystem designed to produce an industry survey of industrial capacity, maximum output, and/or output trends. The system also includes (7) an adjustment subsystem designed to adjust individual facility output to adjust and/or maximize overall all industrial output.
In all of the above systems, the imaging subsystem can be adapted to image stack plumes to determine temperature and compositional profiles of the plume intermittently, periodically, semi-continuously, or continuously. Thermal and compositional data can either be obtained using a single camera system with different filters that select light characteristic of a given atomic and/or molecular species or using composition specific cameras or sensors in parallel or series. In the case of a single camera system, the imaging system can include a series of filter that are intermittently, periodically or continuously interchanged so that each image type is acquired on an intermittent, periodic or continuous basis. It should be recognized that each data collection for each different filter can be continuously collected or collected over a period of time and if over a period of time, each acquisition period can be the same of different. It should also be recognized that operating in a continuous switching mode does not mean that the collected data for each filter is temporally continuous (clearly when one image is being collected, the other images are not), but that each image type is being collected in a continuous rotation during a given monitoring period. Such a continuous switching mode of operation can be contrasted with a mode where one image type is collected continuously, except for intermittent or periodic collections of the other image types. Thus, the data from the first image type will be temporally much more complete, save for the time required to switch from its filter to a second filter, to collect a data set or image from the second filter and switch back, while the data from the second image type will be intermittent or periodic, with large temporal gaps between the collected data sets or images. Clearly, the data from the first image type will be periodic if the data from the second image type is periodic, but the first data set will have only small temporal data gaps, while the second data set will have large temporal data gaps.
For imaging subsystems having multiple detectors, cameras or sensors, the subsystem can either utilized multiple images (e.g., each camera or sensor can collect its own light) or the subsystem can include one or more beam splitters capable of splitting a single image into a plurality of images. Thus, a single image can be used by all detectors or the number of light collections, images, can be less than or equal to the number of detectors in the imaging subsystem. It should be recognized that the detectors, cameras or sensors convert incident light in an electronic signal that is capable of being analyzed. Generally, the initial electronic signal is an analog signal that is converted into a digital system prior to analyzing the data.
Methods
The present invention provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks of and/or effluent plumes generated by an industrial facility and/or a unit and/or units thereof. Once the image data has been acquired, the method also includes the step (2) analyzing or converting the image data into plant output activity or capacity utilization data.
The present invention also provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks of and/or effluent plumes generated by an industrial facility and/or a unit and/or units thereof. Once the image data has been acquired, the method also includes the step (2) processing the image data to correct the image data for existing environmental factors. After image correction, the method also includes the step (3) analyzing or converting the corrected image data into plant output activity or capacity utilization data.
The present invention also provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks and/or effluent plumes generated by an industrial facility or units thereof. Once the image data has been acquired, the method also includes the step (2) analyzing or converting the image data into plant output activity or capacity utilization data. After data conversion, the method also includes the step of (3) accumulating the plant output activity or capacity utilization data. After data accumulation, the method also includes the step of (4) generating data trends derived from the plant output activity or capacity utilization data.
The present invention also provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks and/or effluent plumes generated by an industrial facility or units thereof. Once the image data has been acquired, the method also includes the step (2) correcting the image data for existing environmental factors. After image data correction, the method also includes the step (3) converting the corrected image data into plant output activity or capacity utilization data. After data conversion the method also includes the step (4) accumulating the plant output activity or capacity utilization data over time. After data accumulation, the method also includes the step (5) generating trends in plant output activity or capacity utilization data.
The present invention also provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks and/or effluent plumes generated by an industrial facility or units thereof. Once the image data has been acquired, the method also includes the step (2) converting the image data into plant output activity or capacity utilization data. After data conversion, the method also includes the step (3) accumulating the plant output activity and capacity utilization data. After data accumulation, the method also includes the step (4) generating trends in plant output activity or capacity utilization data and (5) generating reports derived from the plant output activity or capacity utilization and generated trends for end users.
The present invention also provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks and/or effluent plumes generated by an industrial facility or units thereof. Once the image data has been acquired, the method also includes the step (2) correcting the image data for existing environmental factors. After data correction, the method also includes the step (3) converting the corrected image data into plant output activity or capacity utilization data. After data conversion, the method also includes the step (4) accumulating the plant output activity or capacity utilization data over time. After data accumulation, the method also includes the step (5) generating trends in plant output activity and capacity utilization data and (6) generating reports derived from the plant output activity or capacity utilization and generated trends for end users.
The present invention also provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks and/or effluent plumes generated by an industrial facility or units thereof. Once the image data has been acquired, the method also includes the step (2) converting the image data into plant output activity or capacity utilization data. After data conversion, the method also includes the step (3) accumulating the plant output activity or capacity utilization data over time. After data accumulation, the method also includes the step (4) generating trends in plant output activity or capacity utilization data and (5) generating reports derived from the plant output activity or capacity utilization and generated trends for end users. The method can also include the step of (6) adjusting individual facility output to adjust and/or maximize overall all industrial output or any part thereof.
The present invention also provides a method for monitoring and determining plant output activity or capacity utilization including the step of (1) imaging or acquiring image data of stacks and/or effluent plumes generated by an industrial facility or units thereof. Once the image data has been acquired, the method also includes the step (2) correcting the image output data for existing environmental factors. After data correction, the method also includes the step (3) converting the corrected image data into plant output activity or capacity utilization data. After data conversion, the method also includes the step (4) accumulating the plant output activity or capacity utilization data over time. After data accumulation, the method also includes the step (5) generating trends in the plant output activity or capacity utilization data and (6) generating reports derived from the plant output activity or capacity utilization and generated trends for end users The method can also include the step of (7) adjusting individual facility output to adjust and/or maximize overall all industrial output or any part thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following detailed description together with the appended illustrative drawings in which like elements are numbered the same:
FIG. 1A depicts a block diagram of an embodiment of a plant monitoring system of this invention;
FIG. 1B depicts a block diagram of another preferred embodiment of a plant monitoring system of this invention;
FIG. 1C depicts a side view of a system of either FIG. 1A or FIG. 1B ;
FIGS. 1D-E depict two views of another embodiment of mount assembly of this invention;
FIG. 2A depicts a block diagram of another embodiment of a plant monitoring system of this invention;
FIG. 2B depicts a block diagram of another preferred embodiment of a plant monitoring system of this invention;
FIGS. 3A&B depict a block diagram of another embodiment of an imaging apparatus of this invention:
FIG. 3C depicts an imaging apparatus of FIGS. 3A&B mounted on a pole:
FIG. 3D depicts a cross-sectional view of the mount of FIG. 3C :
FIG. 4 depicts an embodiment of an imaging apparatus with multiple filters of this invention,
FIG. 5 depicts an embodiment of a multiple camera imaging apparatus of this invention:
FIG. 6 depicts an embodiment of an imaging apparatus with a beam splitter of this invention,
FIG. 7 depicts another embodiment of an imaging apparatus with a compound beam splitter of this invention:
FIG. 8 depict a block diagram of an embodiment of a multi-site system of this invention:
FIG. 9 depicts a conceptual flow chart of a process of initializing, calibrating and establishing a one hundred percent output capacity value for a given plant or plant unit;
FIG. 10 depicts a conceptual flow chart of a process a plant output monitoring, transmitting and collecting process of this invention;
FIG. 11 depicts a conceptual flow chart of another process a plant output monitoring, transmitting and collecting process of this invention;
FIGS. 12A-C depict three conceptual flow charts of three subprocesses for processing an acquired image to obtain pixel density data;
FIG. 13 depicts a plot of data collected form a three stack facility showing the thermal data image of the three stack in the facility from an IR camera located approximately 1 km from the facility; and
FIG. 14 depicts a plot of daily output activity for the facility in FIG. 13 .
DETAILED DESCRIPTION OF THE INVENTION
The inventors have found that a system and method can be constructed that uses IR cameras to determine intermittent, periodic, near instantaneous, and/or instantaneous plant capacities of plants of a desired industry. The system and method are designed to utilize data obtained from an IR camera imaging exhaust plumes from exhaust outputs such as stacks outputs. These images are designed to be obtained on an intermittent, periodic, near instantaneous, and/or instantaneous basis and plume size data are then related to plant activity. The activity data is then used to project overall unit, plant, regional, national, or industrial output to allow for intermittent, periodic, near instantaneous, and/or instantaneous adjustments to overall industrial output so that industrial output across the spectrum can be evened out and/or maximized. The system and method is designed to accumulate data for a sufficient time to determine a base line for determining a particular plant's activity profile so that plume image data can be directly related to plant output within a given confidence level. The system is also designed to provide end users to access unit, plant, regional, industry wide, etc. data on output activity, capacity utilization, emissions, effluent volumes, etc. for forecasting purposes, supply and demand analyses and other industrial indicators. All of the data analyses performed for end users is subject to pricing for revenue generation purposes.
The present invention relates broadly to a system for monitoring and determining plant output capacity including an imaging subsystem capable of imaging effluent plumes generated by an industrial facility or units thereof and producing image output data and an analysis subsystem for converting the image data into plant output capacity data.
The present invention provides a method for monitoring and determining plant output capacity including an imaging subsystem capable of imaging effluent plumes generated by an industrial facility or units thereof and producing image output data and an analysis subsystem for converting the image data into plant output capacity data.
In order to monitor plant output activity or capacity utilization, a detection device is adapted to observe and/or monitor one property or a plurality of properties of the plant that can be related to plant output activity or capacity utilization. One such property of a plant that can be monitored at a distance is heat associate with thermal stacks and/or stack exhaust effluent streams. For plants that exhaust gases, the detection device is adapted to image an exhaust stack and/or a plume associated with the exhaust stack. The area/volume of the exhaust plume or the stack as imaged by an imaging apparatus such as an IR camera is captured at a given moment in time, continuously captured, or accumulated for a period of time at regular intervals to establish a plant base line or a mean average value of plant output activity or capacity utilization. In the case continuous imaging apparatuses, continuous images are taken over a short period of time at regular intervals, where the images taken over the short periods of time are accumulated to form a single composite image. If the base line or mean average value does not vary by more than a set amount, then the mean average value is set to a 100 percent value. As monitoring continues, deviations from the 100 percent value will either indicate a reduce in plant output or an increase in plant output. If the increase is maintained for a non-temporary time, the a new 100 percent value is established. If the 100 percent value originally collected is consistent over time, then changes in the measured value will represent disruptions in the plant output, generally decreases in plant output. If the system is designed to measure non-nuclear power generation facilities, then the data can be used to predict disruptions in the grid and to adjust individual plant outputs to maintain a given level of overall output, to maximize overall output or to adjust overall output to some desired level. In the case of a nuclear power generation facility, the monitor is designed to monitor output water used in the secondary coolant loop in a nuclear power facility or in the effluent water to monitor water temperature, output and to look for detectable radio-pollutants.
The system is designed to monitor plant activity from a distance. Generally, the distance can be between about 25 m (meters) to about 10 km (kilometers) depending on the type of imaging device being utilized. Preferably, the distance is between about 100 m and about 5 km and particularly between about 100 m and about 1 km.
When the system first starts monitoring a given plant, it will not know whether the plant is operating a full capacity. Thus, the system is designed to accumulate data over a sufficient period to time to ascertain whether a given plant output remains substantially constant over the period of time, where the term substantially constant means that the plant output does not deviated more than about 10% over the period of time. In another preferred embodiment, the plant output does not deviate more than about 5% over the period of time. The in yet another preferred embodiment, the plant output does not deviate more than about 1% over the period of time. The period of time is generally a month, preferably, two weeks and, particularly, one week. Once the output of a plant has been determined, its 100 percent is entered into a database.
Generally, plant output data is acquired periodically over the period of time. The period for data acquisition is generally between the acquisition rate of the imaging device, if not continuous, and about 1 day. In a preferred embodiment, the acquisition rate is between about 1 second and 1 hour. In yet another embodiment, the acquisition rate is between about 1 minute and about 1 hour. In yet another embodiment, the acquisition rate is between about 5 minutes and about 45 minutes. In yet another embodiment, the acquisition rate is between about 10 minutes and about 30 minutes. In yet another embodiment, the acquisition rate is between about 10 minutes and about 20 minutes. In yet another embodiment, the acquisition rate is between about 15. This same data acquisition rate is also used for continued monitoring.
Data is then collected for plants within a given industry to form a database for that industry. Once the database is constructed, monitoring allows the system to detect on an instantaneous, a near instantaneous, periodic or intermittent basis alterations in the output of each plant in the given industry. Upon the detection of a disruption in the overall output of a given industry, information associated with the disruption can be sent to local, state and federal oversight agencies and the data can be distributed to other plants within the given industry of the change in overall capacity so that the other plants can adjust their output to compensate for the disruption.
The present invention also relates to a business method for detecting, tracking, compiling and distributing information on an industry-by-industry basis to permit any given industry to adjust specific plant activities so that an overall industrial output can be maintained, adjusted and/or maximized. The information will, of course, be associated with a fee associated with the monitoring, tracking, compiling and distributing of the acquired data. Thus, the present invention also relates to an industry output clearinghouse, where members of a given industry will subscribe to the clearinghouse and will be given data on a continuous, semi-continuous, periodic and/or intermittent basis concerning overall industrial output, output trends, specific plant output data and/or alters signifying changes in the output of one, some or all plants within the given industry. The clearinghouse data will better allow industrial players to determine overall industrial needs and treads and to better adjust individual plant outputs to maintain, adjust, minimize and/or maximize industrial overall output or activity. The clearinghouse data will also be able to identify quickly changes in a specific plant output such as a plant undergoing a de-bottlenecking operations or other modifications to increase plant output. The clearinghouse will give industry players quick and reliable data for maximizing profits, output and/or expenditures to increase specific plant capacity. The clearinghouse data will also show longer term trends in given industries and be able to identify early regional output disruptions or regions where additional capacity is needed to keep up with demand. The data will also allow industrial players to better positions its output capacity to maximize return on investment and to maximize profits and minimize losses.
Suitable IR cameras include, without limitation, IR cameras manufactured by Honeywell Corporation, Thermoteknix Systems Ltd of Cambridge, England (Visir camera, Miric 500, Miric 11, etc.), Infrared Solutions Inc. of Minneapolis, Minn., USA (IR-160), FLIR Systems, Inc. of North Billerica, Mass., USA (A series infrared camera, Thermovision 2000, Thermovision Ranger II and Sentry, etc.), Diversified Optical Products, Inc. of Salem, N.H., USA (Lanscout 50, 75, 125, Lanscout 60/180, Range Pro 50/250, etc.), Leake Company of Dallas, Tex., USA (Thermal Sentry), Spirit Solutions, Inc., and other similar IR camera systems. Preferably, the cameras employ an infrared array detection system. Infrared array detections systems are available from Raytheon Company of Waltham, Mass., USA, DRS Technologies, Inc., Santa Barbara Research Center, University of California at Santa Barbara, Cal Sensors, Inc. of Santa Rosa, Calif., USA, HGH Systèmes Infrarouges ZAC, IGNY, FRANCE, ULIS of Veurey Voroize France, and other manufactures that make IR array detectors. It should be recognized that there are different array technologies. Several of these technologies include Amorphous Silicon (ASi) Focal Plane Array (FPA) and Barium Strontium Titanate (BST) FPA. Currently, the inventors have had their best results with the BST FPA array.
Suitable compositional detectors include, without limitation, any detector that is capable of detecting light characteristic of a given atomic and/or molecular system. Generally, the detectors are optimized for a particular wavelength of light and filters are used to eliminate light not in the detectors spectral sensitive regions. However, a detector can be used with broad and uniform response characteristics, with light restriction occurring by judicious selection of filters designed to pass light of a desired wavelength range, where the range is characteristic of a certain chemical compound of class of chemical compounds that have a similar optical emission spectrum within the range. One of ordinary skill in the art are aware of such filters that are selectively sensitive to hydrocarbon optical (Visible, IR, nearIR, microwave, etc.) signatures, nitrogen oxide optical signatures, sulfur oxide optical signatures, water (liquid and/or vapor) optical signatures, carbon oxide optical signatures, etc.
Suitable digital processing units include, without limitation, computers having an processing chip and memory chips manufactured by Intel, Motorola, AMD, Cyrix, Erickson, or mixtures or combinations thereof. The digital processing units include peripheral such as, without limitation, internal and/or external mass storage devices such as disk drives, solid state disk drives, tape drives, memory stick, memory cards, etc., communication hardware and software, printers, scanners, etc.
Single Imaging Subsystem—Plume Imaging
Referring now to FIG. 1A , a preferred embodiment of an IR imaging system of this invention, generally 100 , is shown to include an imaging assembly 102 . In one embodiment, the imaging assembly 102 includes a pole 104 , a mount assembly 106 disposed on a top 108 of the pole 104 and an imaging unit 110 mounted on the mount assembly 106 . One of ordinary skill in the art should recognize that the imaging assembly 102 can extend from the ground, from the top of a building, or from any other object that allows the imaging unit 110 to have a clear line of sight image of the target plant or plant stacks that are used to obtain information on plant or plant unit activity and to obtain other information including a monitor of the type of materials being exhausted from the stacks. Of course, if the effluent is a liquid, such as waste water, the imaging unit 110 would be situated to image the effluent. If effluent compositional data are being collected as well as plant or plant unit output capacity data, then the imaging unit may include more than one imaging camera, each having a different filter or the imaging unit is capable of collecting data over a large frequency range and the resulting image data can be mathematically filtered.
The imaging assembly 102 is located a specific distance from a plant 112 , which is shown to have four exhaust stacks 114 a - d , which are monitored to determine the plant's output at any given time. The imaging unit 110 is positioned so that the imaging unit 110 can acquire an image 116 which includes four active regions 118 a - d associated with the four stacks 114 a - d , respectively. Of course, if it is determined that the four stack produce equal plant capacity data (each stack accounts for ¼ of the plant output), then only one active region need be analyzed.
The imaging system 100 also includes a remote processing center 120 in data communication with the imaging unit 110 via a data flow pathway 122 . The data communication can be wireless or wired. If wireless, the data communication can line of sight or more preferably the signal can be transmitted via cell phone networks or satellite networks onto a distributed network such as the internet or a secured distributor network.
Multiple Imaging Subsystem—Plume Imaging
Referring now to FIG. 1B , another preferred embodiment of an IR imaging system of this invention, generally 150 , is shown to include four imaging assemblies 152 a - d . In one embodiment, each of the imaging assemblies 152 a - d includes a pole 154 a - d , a mount assembly 156 a - d disposed on a top 158 a - d of the pole 154 a - d and an imaging unit 160 a - d mounted on the mount assemblies 156 a - d , respectively. One of ordinary skill in the art should recognize that the imaging assemblies 152 a - d can extend from the ground, from the top of a building, or from any other object that allow the imaging units 160 a - d to have a clear line of sight image of the plant stacks that are used to obtain information on plant or plant unit activity and to obtain other information including a monitor of the type of materials being exhausted from the stacks. Of course, if the effluent is a liquid, such as waste water, the imaging units 160 a - d would be situated to image the effluent. If effluent compositional data are being collected as well as plant or plant unit output capacity data, then the imaging units may include more than one imaging camera, each having a different filter or the imaging units are capable of collecting data over a large frequency range and the resulting image data can be mathematically filtered.
Each of the imaging assemblies 152 a - d is located a specific distance from a plant 162 , which is shown to have four exhaust stacks 164 a - d , so that the assembly 152 a is focused on the stack 164 a , the assembly 152 b is focused on the stack 164 b , the assembly 152 c is focused on the stack 164 c , and the assembly 152 d is focused on the stack 164 d . This configuration allows each stack to be separating monitored which can increase the amount and type of information extractable from the images. This configuration is especially useful when the output stack of interest are incapable of being efficiently imaged from a single location or the distance from the imaging unit prevents ready complete imaging as in FIG. 1A .
Each of the imaging units 160 a - d is positioned so that each of the imaging unit 160 a - d can acquire an image 166 a - d which includes a stack active region 168 a - d , respectively.
The imaging system 150 also includes a remote processing center 170 in data communication with the imaging units 160 a - d , via data flow pathways 172 a - d . The data communication can be wireless or wired. If wireless, the data communication can line of sight or more preferably the signal can be transmitted via cell phone networks or satellite networks onto a distributed network such as the internet or a secured distributor network.
Imaging Subsystem Views—Plume Imaging
Referring now to FIG. 1C , a side view of the plant configuration of FIGS. 1A&B is shown. The view show an imaging assembly 102 or 152 and the distance D to the stacks and the resulting vertical image positioning V resulting from a view angle A. The apparatus 100 also includes a processing unit 170 in electrical communication via a communication pathway 172 (which can be a cable supporting wired based data communication or a wireless format supporting wireless data communication) with the imaging unit (camera) 110 . The processing unit 170 generally includes computer hardware and software and communication hardware and software need to capture, store, analyze and/or transmit the image data captured by the imaging unit 110 to the central processing center 120 .
Referring now to FIGS. 1D-E , a preferred embodiment of the mount assembly 106 or 156 a - d is shown to include a portion 124 of the pole 104 or 154 a - d . Mounted on the top 108 or 158 a - d of the pole 104 or 154 a - d , respectively, is mount 126 supporting a shaft 128 , which is attached to the imaging unit 110 or 160 a - d via a ball joint 130 . The ball joint 130 allows the imaging unit 110 or 160 a - d to be adjusted up and down 132 as shown in FIG. 1D or side to side 134 as shown in FIG. 1E . Of course, the imaging unit 110 or 160 a - d can be mounted on the mount 126 by any assembly that permits the imaging unit 110 or 160 a - d to be adjusted in two orthogonal directions, e.g., up and down and side to side. Moreover, the assembly can be motorized so that the imaging unit can be adjusted remotely. Such remote adjust capability can be used to allow the imaging unit to image specific areas of interest. Furthermore, the imaging unit aperture can be motorized under remote control so that the imaging unit can be controlled to image a specific area and to limit the image being captures. The imaging unit can also be equipped with magnifying lens to further refine the imaged area.
Single Imaging Subsystem—Stack and Plume Imaging
Referring now to FIG. 2A , another embodiment of an IR imaging system of this invention, generally 200 , is shown to include an imaging assembly 202 . The imaging assembly 202 includes a pole 204 , a mount assembly 206 disposed near a top 208 of the pole 204 and an imaging unit 210 mounted on the mount assembly 206 . One of ordinary skill in the art should recognize that the imaging assembly 202 can extend from the ground, from the top of a building, or from any other object that allows the imaging unit 210 to have a clear line of sight image of the target plant or plant stacks that are to be used to obtain information on plant or plant unit activity and to obtain other information including monitoring the type of materials being exhausted from the stacks. Of course, if the effluent is a liquid, such as waste water, the imaging unit 210 would be situated to image pipe near its exit and the effluent issued therefrom. If effluent compositional data are being collected as well as plant or plant unit output activity and capacity utilization data, then the imaging unit may include more than one imaging camera and/or detector, each having a different filter or the imaging unit is capable of collecting data over a large frequency range and the resulting image data can be physically or mathematically filtered pre- or post-data acquisition.
The imaging assembly 202 is located a specific distance from a plant 212 , which is shown to include four exhaust stacks 214 a - d , which are monitored to determine the plant's output activity or capacity utilization at any given time or time interval. The imaging unit 210 is positioned so that the imaging unit 210 can acquire an image 216 which includes four the four stacks 214 a - d and four active regions 218 a - d associated with the four stacks 214 a - d , respectively. Of course, if it is determined that the four stack produce equal plant output activity or capacity utilization data (each stack accounting for ¼ of the plant output), then only one stack and/or active region need be analyzed.
The imaging system 200 also includes a remote data storage, processing and analyzing center 220 in data communication with the imaging unit 210 via a data flow pathway 222 . The data communication can be wireless or wired. If wireless, the data communication can line of sight or more preferably the signal can be transmitted via cell phone networks or satellite networks onto a distributed network such as the internet or a secured distributor network.
The imaging unit 210 also includes a power conditioning unit 224 connected to a power grid (not shown) and to the imaging unit 210 via a power supply line 226 . The imaging unit 210 also includes a lightening rod 228 connected to a ground 230 by a ground wire 232 . The assembly 202 also includes a protective top shield 234 .
Multiple Imaging Subsystem—Stack and Plume Imaging
Referring now to FIG. 2B , another embodiment of an IR imaging system of this invention, generally 250 , is shown to include four imaging assemblies 252 a - d . In one embodiment, each of the imaging assemblies 252 a - d includes a pole 254 a - d , a mount assembly 256 a - d disposed on a top 258 a - d of the pole 254 a - d and an imaging unit 260 a - d mounted on the mount assemblies 256 a - d , respectively. One of ordinary skill in the art should recognize that the imaging assemblies 252 a - d can extend from the ground, from the top of a building, or from any other object that allow the imaging units 260 a - d to have a clear line of sight image of the plant stacks that are used to obtain information on plant or plant unit activity and to obtain other information including a monitor of the type of materials being exhausted from the stacks. Of course, if the effluent is a liquid, such as waste water, the imaging units 260 a - d would be situated to image the effluent. If effluent compositional data are being collected as well as plant or plant unit output capacity data, then the imaging units may include more than one imaging camera, each having a different filter or the imaging units are capable of collecting data over a large frequency range and the resulting image data can be mathematically filtered.
Each of the imaging assemblies 252 a - d is located a specific distance from a plant 262 , which is shown to have four exhaust stacks 264 a - d , so that the assembly 252 a is focused on the stack 264 a , the assembly 252 b is focused on the stack 264 b , the assembly 252 c is focused on the stack 264 c , and the assembly 252 d is focused on the stack 264 d . This configuration allows each stack to be separating monitored which can increase the amount and type of information extractable from the images. This configuration is especially useful when the output stack of interest are incapable of being efficiently imaged from a single location or the distance from the imaging unit prevents ready complete imaging as in FIG. 2A .
Each of the imaging units 260 a - d is positioned so that each of the imaging unit 260 a - d can acquire an image 266 a - d which includes the stacks 264 a - d and stack active regions 268 a - d , respectively.
The imaging system 250 also includes a remote processing center 270 in data communication with the imaging units 260 a - d , via data flow pathways 272 a - d . The data communication can be wireless or wired. If wireless, the data communication can line of sight or more preferably the signal can be transmitted via cell phone networks or satellite networks onto a distributed network such as the internet or a secured distributor network.
The imaging units 260 a - d also include power conditioning units 274 a - d connected to a power grid (not shown) and to the imaging units 260 a - d via power supply lines 276 a - d . The imaging units 260 a - d also include lightening rods 278 a - d connected to grounds 280 a - d by ground wires 282 a - d . The assemblies 252 a - d also includes protective top shields 284 a - d.
Alternate Single Imaging Subsystem
Referring now to FIGS. 3A&B , another embodiment of an imaging apparatus of this invention, generally 300 , is shown to include a housing 302 having a front half 304 including a handle 306 attached to a front surface 308 thereof and a back half 310 including a back surface 312 adapted to permit the housing 302 to be mounted on a mount as shown in FIG. 3C . The housing 302 also includes a pair of hinges 314 adapted to permit the housing 302 to be opened by pulling on the handle 306 . Of course, the handle can and generally will be a locking handle which requires a key for entry. Alternatively, the housing 302 can be equipped with a keyless entry system that is can be activated by a remote control or via commands issued from a central control facility to prevent unauthorized entry into the apparatus 300 .
The front surface 308 include an aperture 316 through which light can pass through a camera lens 318 . The apparatus 300 also includes an antenna 320 mounted on the surface 308 near its top 322 having a wire 324 leading to communication hardware to be described below.
Once the apparatus 300 is opened as shown in FIG. 3B , the apparatus 300 includes a camera 326 mounted in the front half 304 of the housing 302 so that its lens 308 centered in the aperture 316 . The apparatus 300 also includes a digital processing unit (DPU) 328 , a video analog to digital converter 330 , and a communication device 332 such as a PIMCIA slot 334 with a mobile access card 336 .
The DPU 328 is powered by a DPU power supply 338 mounted in the back half 310 of the housing 302 via a DPU power cable 340 ; while the camera 326 is powered by a camera power supply 342 mounted in the back half 310 of the housing 302 via a camera power cable 344 The apparatus 300 also includes two fans 346 a & b mounted in the back half 310 of the housing 302 .
The DPU 328 is in two-way communication with the camera 326 via a first electronic connection 348 , with the converter 330 via a second electronic connection 350 and with the communication device 332 via a first electronic connection 352 . The communication device 332 is also connected to the antenna 320 via the wire 324 , where the antenna is adapted to permit robust communication between the apparatus 300 and a remote command and control site located remote from the site of installation of the apparatus 300 via satellite, microwave or other broadband or narrow band technology capable of transmitted data from the apparatus 300 to a remote site. Alternatively, the apparatus 300 could have a cable or fiber optics direct connection between the apparatus 300 and the remote control and command center.
The apparatus 300 also includes a power strip 354 connected to an external power conditioner and uninterrupted power supply 356 via a power in cable 358 . The power supply 356 can be an outdoor uninterrupted power supply (UPS) with 400 w output for up to 18 hr, 12-14 hr actual. The DPU power supply 338 derives its power from the strip 354 via a first strip cable 360 ; the camera power supply 342 derives its power from the strip 354 via a second strip cable 362 ; and the two fans 346 a & b derive their power from the strip 354 via third and fourth strip cables 364 a & b.
Referring now to FIG. 3C , the apparatus of FIGS. 3A&B is shown mounted on a pole 366 via a mounting apparatus 368 having two degrees of rotational freedom, up and down adjustability and in and out adjustability. The pole 366 includes a lightening rod 370 connected to a ground 372 via a ground wire 374 .
One embodiment of the mounting apparatus 368 includes a rotational ball-pen assembly 376 having a locking screw, set screw or thumb screw 378 is shown in FIG. 3D . The ball-pen assembly 376 includes a ball housing 380 affixed to a up and down translation platform 382 and a ball 384 having a neck 386 affixed to a monitoring apparatus mount 387 affixed to a back surface 312 of the back half 310 of the housing 302 . The ball-pen assembly 376 permits the monitoring apparatus 300 to be tilted so that its camera aperture 316 is properly aligned with the stack or other object that the monitoring system 300 is installed to monitor (stacks, refinery units, heat exchange units, chemical reactor units, power plant water outlets, steam generation units, etc.). The translation platform 382 is adapted to translate via a groove 388 in a pole mounting plate assembly 390 . The translation platform 382 is held in place by to groove engaging screws 392 . The pole mounting plate assembly 390 includes a pole plate 394 affixed to the pole 366 and an adjustable plate 396 , which comprises the groove into which the translation platform 382 is mounted. The adjustable plate 396 is adapted to be separated from the pole plate 394 by screws 398 , which force the plates 394 and 396 to separate or come together depending on the direction the screws are turned. Other mounting apparatuses can be used as well provided that they at least permit two degrees of rotational freedom so that the camera aperture of the monitoring unit can be properly aligned with the object to be imaged. Up and down and in and out adjustability are optional, but are often found to be beneficial then installing the unit as the mounting apparatus does not have to be very precisely attached to the pool. Of course, the extent of rotation freedom will be limited by the ball-pen assembly and the size and weight of the monitoring unit, the size and weight of the mounting apparatus and other factors all within the design capability of an ordinary artisan in the field of mounting equipment on poles with differing rotational and/or translational degrees of freedom. The types of mounts that can be used are any camera or telescope mount that provides at least two rotational degrees of freedom, where translation and in and out adjustment can be made when the unit is being installed or translational adjustment can simply be an adjustable pole strapping assembly.
Multi-Detector Imaging Subsystem
Referring now to FIG. 4 , an embodiment of an imaging apparatus with multiple filters of this invention, generally 400 , is shown to include a camera housing 402 . The camera housing 402 includes a camera 404 having an aperture 406 through which light passes into the camera's interior. The camera housing 402 also includes a four filter carousel 408 including four filters 410 a - d . The carousel 408 is mounted on a drive shaft 412 of a motor 414 . The motor 414 is adapted to change filters so that the camera can be used to view different properties of the target site such as thermal emission profiles, effluent components (S x O y , N x O y , CO 2 , hydrocarbons, water, etc. or mixtures or combinations thereof, where x is an integer having a value between 1 and 3 and y is an integer having a value between 1 and 8). The motor 414 is adapted to be controlled by the DPU 328 so that the system 300 can collect data on different properties of the site by selectively switching between filters. The apparatus 400 can be used with any of the imaging apparatuses of FIGS. 1-3 .
Referring now to FIG. 5 , an embodiment of a multiple camera imaging apparatus of this invention, generally 500 , is shown to include a housing 502 . The housing 502 includes four filters 504 a - d and four cameras 506 a - d having their apertures 508 a - d aligned with the filters 504 a - d so that light passes through the filters 504 a - d through the apertures 508 a - d and into the cameras 506 a - d . The cameras 506 a - d are connected to the DPU or to the converter and then the DPU, where the DPU is designed to capture, process and transmit the captured camera data. The apparatus 500 can be used with any of the imaging apparatuses of FIGS. 1-3 .
Referring now to FIG. 6 , an embodiment of an imaging apparatus with a beam splitter of this invention, generally 600 , is shown to include a housing 602 . The housing 602 includes surface mounted two filters 604 a - b and two single detector cameras 606 a - d having their apertures 608 a - b aligned with the filters 604 a - b so that light passes through the filters 604 a - b through the apertures 608 a - b and into the cameras 606 a - b . The housing 602 also includes a multi-detector optical detection apparatus or camera 610 having a detector aperture 612 situated within a housing aperture 614 in the housing. Light entering through the detector aperture 612 is split into two beams 616 a - b by a beam splitter 618 . The first light beam 616 a passes through a first detector filter 620 a and into a first detector 622 a , while the second light beam 616 b passes through a second detector filter 620 b and into a second detector 622 b . The two single channel cameras 606 a - b and the multi-channel camera or optical detector 610 are connected to the DPU or to the converter and then the DPU, where the DPU is designed to capture, process and transmit the captured camera data. The apparatus 600 can be used with any of the imaging apparatuses of FIGS. 1-3 .
Referring now to FIG. 7 , another embodiment of an imaging apparatus with a compound beam splitter of this invention, generally 700 , is shown to include a housing 702 . The housing 702 includes a multi-detector optical detection apparatus or camera 704 having a detector aperture 706 situated within a housing aperture 708 in the housing. Light entering through the detector aperture 706 is split into four beams 710 a - d by a compound beam splitter 712 . The first light beam 710 a passes through a first detector filter 714 a and into a first detector 716 a ; the second light beam 710 b passes through a second detector filter 714 b and into a second detector 716 b ; the third light beam 710 c passes through a third detector filter 714 c and into a third detector 716 c ; while the fourth light beam 710 d passes through a fourth detector filter 714 d and into a fourth detector 716 d . The multi-channel camera or optical detector 704 is connected to the DPU or to the converter and then the DPU, where the DPU is designed to capture, process and transmit the captured camera data. The apparatus 700 can be used with any of the imaging apparatuses of FIGS. 1-3 .
Multi-Site System
Referring now to FIG. 8 , an embodiment of a multi-site system of this invention, generally 800 , shown to include a center facility 802 that includes computer hardware and software, communications hardware and software and sufficient servers to support a plurality of site monitoring system 804 a - z , where the term a plurality means between 2 and a number limited only by the number of sites amenable to monitoring by this type of a system. Clearly, the upper limit can be many thousands if not many hundreds of thousands of sites. The sites 804 a - z are in data communication with the facility 802 via communication pathways 806 a - z , which can be wired and/or wireless, but most often will be wireless. Of course, if the data is being transmitted via a commercial or private broadband wireless provider, part of the connection can be wireless and part wired, where the wired part would represent data being received wireless into an intranet (private internet) or open internet like the world wide web.
The data from the monitoring system 804 a - z , can be raw data, partially processed data or fully processed data. The facility 802 receives this data as is and performs would ever additional data processing required to obtain site specific data—capacity utilization or output activity data, effluent compositional data, effluent production volume data, etc. This process data is then stored on a site specific basis in database on the servers in the facility 802 . This accumulated data can then be analyzed on any combination of monitoring systems basis. Thus, if monitoring is occurring at all sites of a particular type such as power plants, then grid integrity reports can be generated to show trends, to identify problems and to predict future supply, demand and pricing.
The system 800 also includes a plurality of end users 808 a - z , where the end user plurality can be from 2 to a very large number into the millions of end users. Each end user 808 a - z is are in data communication with the facility 802 via communication pathways 810 a - z , which can be wired and/or wireless, but most often will be wireless. Of course, if the data is being transmitted via a commercial or private broadband wireless provider, part of the connection can be wireless and part wired, where the wired part would represent data being received wireless into an intranet (private internet) or open internet like the world wide web.
Methods for Collecting, Analyzing and Distributing Plant Activity or Utilization Data
Referring now to FIG. 9 , an embodiment of a process to obtain a one hundred percent plant or plant unit output capacity, generally 900 , shown as a flow chart diagram. The process 900 includes a start step 902 , which becomes active after the imaging apparatus has been installed at a desired site. After installation, the imaging unit is set up in a set step 904 , which generally involves insuring that all component of the imaging unit are working, that the imaging unit is in communication with the remote processing center and insuring that the imaging unit is functioning properly. Once the imaging unit is set up, the imaging unit is adjusted in an adjustment step 906 by rotating and/or translating the unit on its mount so that the imaging camera or cameras are property aligned with the site to be monitored. A test image is then acquired in an acquisition step 908 . The acquired image is then scanned to define active regions within the image in a define active regions step 910 . The active regions represent that part of the entire image that will be monitored in all subsequent image acquisitions and can include parts of the operational unit such as a stack, piping, heat exchange units, etc. and/or effluent streams or plumes. Once the active regions are defined, the regions are processes to produce data that can be related to plant activity, unit activity, capacity utilization, effluent production, effluent compositions, etc. in a process active regions step 912 . The results are then tested in a conditional pass acquisition test (PAT) step 914 . If the imaging unit has been adjusted so that the acquired image maximizes data collections of the target site(s) within the plant, then control is transferred along a YES branch 916 to an acquire image step 918 ; otherwise control is transferred along a NO branch 920 to the adjustment step 206 . This NO loop is continued until the data passes the conditional test 814 . The acquired image is then processed to compute a plant or unit output value in a process active regions step 922 . The value is then sent to a compare step or self-consistent value (SCV) step 924 , where the current value is compared to a previous value or a set of previous values until the values being compared differ by less than a specified percent error. If the difference is greater than the error, then control is transferred along a NO branch 926 to the acquire image step 818 for reacquisition; otherwise control is transferred along a YES branch 928 to a set 100% value step 930 . Of course, it should be recognized that the 100% is set when the unit or plant is operating at full capacity. When a unit is initially installed, there is not guarantee that the plant or unit being monitored is actually operating at 100% capacity. However, this routine can be used to set an initial 100% value. If later, the value jumps and remains that the actual 100% valve, then the 100% can be updated. This same updating may occur with the plant or unit undergoes modifications, de-bottlenecking, or any other change that can increase or decrease 100% capacity value.
Referring now to FIG. 10 , an embodiment of a process to obtain output capacity data, generally 1000 , shown as a flow chart diagram. The process 1000 begins with a start step 1002 . After the routine is started, an image is acquired in an acquire image step 1004 . The acquired image is then process to extract data from the active regions within the image in a process step 1006 . The active region data is then used to compute output activity, utilization capacity and/or effluent compositional data in a compute step 1008 . The output data is then transmitted to a customer in a transmit step 1010 and a revenue is collected as a result of the transfer in a collect step 1012 . The process 900 also includes a conditional step 1014 , where the process can be stopped by an interruption in collected revenue, discontinuing of an account or by supervisor intervention. If no exit event has occurred, then controlled is transferred along a NO branch 1016 to the acquire image step 304 ; otherwise control is transferred along a YES branch 1018 to a stop step 1020 . Of course, in general, the program will not terminate, but will continue data collection and transmission until no revenue stream is obtained. However, the program could also be continued to accumulate information for periodic compilation and sale. Alternatively, the transmit step 910 can simply be a posting of the results to secure website or a secure server and the end user would simply logon into an account on the website or server and obtain the posted data.
Referring now to FIG. 11 , another embodiment of a process to obtain output capacity data, generally 1100 , shown as a flow chart diagram. The process 1100 begins with a start step 1102 . After the routine is started, an image is acquired in an acquire image step 1104 . The acquired image is then process to extract data from the active regions within the image in a process step 1106 . The active region data is then used to compute output activity, utilization capacity and/or effluent compositional data in a compute step 1108 . The data is then accumulated for a period of time, either set, variable or interruption triggered in an accumulate step 1110 . Control is then transferred to a report period test (RPT) step 1112 . If the period limit or trigger has not occurred, then control is transferred along a NO branch 1114 to the acquire image step 404 ; otherwise control is transferred along a YES branch 1116 to a product output report step 1118 . Once the accumulated output report is produced, the report is transmitted to a customer in a transmit step 1120 and revenue is collected in a collect step 1122 . The process 400 also includes a conditional step 1124 , where the process can be stopped by an interruption in collected revenue, discontinuing of an account or by supervisor intervention. If no exit event has occurred, then controlled is transferred along a NO branch 1126 to the acquire image step 304 ; otherwise control is transferred along a YES branch 1128 to a stop step 1130 . Of course, in general, the program will not terminate, but will continue data collection and transmission until no revenue stream is obtained. However, the program could also be continued to accumulate information for periodic compilation and sale. Alternatively, the transmit step 1020 can simply be a posting of the results to secure website or a secure server and the end user would simply logon into an account on the website or server and obtain the posted data.
Referring now to FIGS. 12A-C , three preferred embodiments of a process active region subprocess are described, generally 1200 , shown as a flow chart diagram. Looking at FIG. 12A , the subprocess starts with an extraction step 1202 , where pixels associated with the active regions are extracted from the acquire image. Next, the “on” pixels are determined within the active regions, i.e., the pixels at containing more than a background pixel intensity or more than a threshold pixel intensity, is a determination step 1204 . The “on” pixel data are then used to output an active regions density data in an output step 1206 . The resulting “on” pixel data is then used in the compute output values steps of FIGS. 9 , 10 and 11 . Of course, the pixel data derived from this process can relate to thermal data or compositional data depending on the light being collected and analyzed.
Looking at FIG. 12B , the subprocess starts with the extraction step 1202 , where pixels associated with the active regions are extracted from the acquire image. Next, the “on” pixels are determined within the active regions, i.e., the pixels at containing more than a background pixel intensity or more than a threshold pixel intensity, is a determination step 1204 . Once the “on” pixels are identified, then weather condition correction factors are applied to the “on” pixel count in apply step 1208 . These corrections are intended to correct the pixel data to compensate for weather conditions. The corrections factors can be determined by either data accumulated over time or from studies of acquired images under different weather conditions at constant plant output. The “on” pixel data are then used to output an active regions density data in an output step 1206 . The resulting “on” pixel data is then used in the compute output values steps of FIGS. 9 , 10 and 11 . Of course, the pixel data derived from this process can relate to thermal data or compositional data depending on the light being collected and analyzed.
Looking at FIG. 12C , the subprocess starts with an adjust step 1210 , where the active regions are corrected for weather conditions, such as a change in wind conditions, change in temperature, etc. After adjusting the active regions, control proceeds to the extraction step 1202 , where pixels associated with the active regions are extracted from the acquire image. Next, the “on” pixels are determined within the active regions, i.e., the pixels at containing more than a background pixel intensity or more than a threshold pixel intensity, is a determination step 1204 . Once the “on” pixels are identified, then weather condition correction factors are applied to the “on” pixel count in apply step 1208 . These corrections are intended to correct the pixel data to compensate for weather conditions. The corrections factors can be determined by either data accumulated over time or from studies of acquired images under different weather conditions at constant plant output. The “on” pixel data are then used to output an active regions density data in an output step 1206 . The resulting “on” pixel data is then used in the compute output values steps of FIGS. 9 , 10 and 11 . Of course, the pixel data derived from this process can relate to thermal data or compositional data depending on the light being collected and analyzed.
Experimental Data Analysis
Referring now to FIG. 13 , a plot of data collected form a three stack facility showing the thermal data image of the three stack in the facility from an IR camera located approximately 1 km from the facility.
Referring now to FIG. 14 , a plot of daily output activity for the facility in FIG. 13 .
All references cited herein are incorporated by reference. While this invention has been described fully and completely, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. Although the invention has been disclosed with reference to its preferred embodiments, from reading this description those of skill in the art may appreciate changes and modification that may be made which do not depart from the scope and spirit of the invention as described above and claimed hereafter. | A monitoring system is disclosed for acquiring output activity, utilization capacity and/or effluent data from an facility on a facility-by-facility and/or an industry-by-industry basis. The system is designed to generate a plant and/or industry output activity database that is updated on a continuous, near continuous, periodic and/or intermittent basis so that subscribers are apprised of changes in plant or overall industry output. A clearing house is also disclosed for distributing the acquired data to subscribers to aid in analyzing, predicting trends, pricing, maintaining, adjusting, minimizing, and/or maximizing individual plant or overall industry output. | 6 |
TECHNICAL FIELD
[0001] The disclosure relates to clutches for torque transmission.
BACKGROUND
[0002] Twin-clutch, twin-shaft, dual shaft, or dual clutch transmissions of the alternating shifting type are well known in the prior art. Various types of twin clutch transmissions have been proposed and put into practical use, particularly in the field of wheeled motor vehicles. Traditional twin clutch transmissions are of a type in which gears are parted into two groups, each group having an individual main clutch, so that the operative condition of each group of gears is carried out by selectively engaging a corresponding main clutch. Twin clutch transmissions are used in vehicles to improve the transition from one gear ratio to another and, in doing so, improve the efficiency of the transmission. The gears of each group are typically individually engaged so as to rotatably connect a transmission input shaft to a transmission output shaft for transmitting torque at differing ratios. The differing ratios may be engaged by multiple shift clutches.
[0003] A typical dual clutch is illustrated in commonly owned U.S. Pat. No. 7,082,850, to Hughes, the disclosure of which is hereby incorporated by reference in its entirety. Many main clutches for dual clutch transmissions include clutch packs, having a plurality of clutch disks, for engaging and disengaging each gear group with the engine. In some applications, the clutches are actuated by hydraulic pistons for engaging and disengaging each clutch pack. Typically, the clutch packs are located radially outside of the hydraulic pistons to prevent fluids that are heated by the clutch packs from contacting the outer surfaces and seals of the piston assemblies.
SUMMARY
[0004] A clutch apparatus includes a clutch pack having a plurality of friction disks. The clutch pack will selectively transfer torque from a torque supplying member to a first torque receiving member. The apparatus also includes a first piston chamber positioned radially outward of the clutch pack. The first piston chamber is operably connected to the clutch pack for exerting a compressive force on at least a portion of the clutch pack as a first fluid is pressurized into the first piston chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Referring now to the drawings, illustrative embodiments are shown in detail. Although the drawings represent some embodiments, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.
[0006] FIG. 1 is a schematic illustration of a vehicle according to an embodiment.
[0007] FIG. 2 is a schematic illustration of a transmission and twin clutch arrangement according to an embodiment.
[0008] FIG. 3 is a partial sectional view of a twin clutch arrangement according to an embodiment.
[0009] FIG. 4 is an enlarged view of portion 4 of FIG. 3 .
DETAILED DESCRIPTION
[0010] FIG. 1 illustrates a powertrain system 20 is shown in accordance with an embodiment. In the illustrated embodiment, the powertrain system 20 includes a prime mover 22 , such as a spark-ignited or compression-ignited internal combustion engine, and a transmission 24 . A shift control system 26 operates to engage and disengage gear ratios within the transmission 24 , as discussed in greater detail below. A main clutch assembly 28 is positioned between the prime mover 22 and transmission 24 to selectively engage/disengage the prime mover 22 from transmission 24 .
[0011] In an embodiment, powertrain system 20 also includes an electronic control unit (ECU) 30 for controlling operation of the prime mover 22 , main clutch assembly 28 generally defining an axis A-A, and transmission 24 . The ECU 30 may include a programmable digital computer that is configured to receive various input signals, including without limitation, the operating speed of the prime mover 22 , transmission input speed, selected transmission ratio, transmission output speed and vehicle speed, and processes these signals accordingly to logic rules to control operation of powertrain system 20 . For example, ECU 30 may be programmed to deliver fuel to the prime mover 22 when the prime mover 22 functions as an internal combustion engine. To support this control, each of the prime mover 22 , and main clutch assembly 28 may include its own control system (not shown) contained within ECU 30 . However, it will be appreciated that the present invention is not limited to any particular type or configuration of ECU 30 , or to any specific control logic for governing operation of powertrain system 20 . A transmission output torque from an output shaft, or output member, 32 is distributed to wheels 34 through a drive shaft 36 and a differential 38 .
[0012] FIG. 2 , illustrates an embodiment of the transmission 24 to include a first input shaft 40 , a second input shaft 42 , a countershaft 44 that extends substantially parallel with first and second input shafts 40 and 42 , and a plurality of gears which are arranged on and/or around shafts 40 , 42 and 44 . Although shafts 40 , 42 and 44 are illustrated as being mounted in a common plane in FIG. 2 , these shafts may be arranged in different planes.
[0013] In the embodiment shown in FIG. 2 , first input shaft 40 is connectable to an output member 46 of the prime mover 22 , such as a flywheel, through a first main clutch C 1 that is used to establish even speed gearing (viz., second speed gearing, fourth speed gearing and reverse gearing), while second input shaft 42 is connectable to flywheel 46 through a second main clutch C 2 that is used for establishing odd speed gearing (viz., first speed gearing, third speed gearing and fifth speed gearing). In an embodiment, first and second main clutches C 1 and C 2 are of a normally ON type, which assumes the ON (viz., engaged) state due to a biasing force of a spring and the like under a normal condition and establishes the OFF (viz., disengaged) state due to work of a hydraulic or electric actuator upon receiving a given instruction. Engagement and disengagement of first and second main clutches C 1 , C 2 may function automatically under the control of ECU 30 , and without intervention of a vehicle driver, when powertrain systems operates like an “automatic” transmission.
[0014] To first input shaft 40 there are connected a 2nd speed input gear 48 , a 4th speed input gear 50 and a reverse input gear 52 , such that gears 48 , 50 and 52 rotate together with first input shaft 40 . Similarly, to second input shaft 42 there are connected a 5th speed input gear 54 , a 3rd speed input gear 56 and a 1st speed input gear 58 , such that gears 54 , 56 and 58 rotate together with second input shaft 42 . The number of input gears provided on first and second input shafts is not limited to the number shown in FIG. 2 , and may include more or less input gears depending on the number of ratios desired in the transmission. The term “gear,” as stated herein, is used to define the toothed wheels schematically illustrated in FIG. 2 , as well as manufacturing the toothed features of the wheels directly into first and second input shafts 40 , 42 and countershaft 44 .
[0015] To countershaft 44 there are rotatably connected a 1st speed output gear 62 , a 3rd speed output gear 64 , a 5th speed output gear 66 , a reverse output gear 68 , a 2nd speed output gear 70 and a 4th speed output gear 72 . Thus, output gears 62 - 72 rotate around countershaft 44 . Like input gears 48 - 58 , the number of output gears provided on countershaft 44 is not limited to the number schematically illustrated in FIG. 2 .
[0016] Referring still to FIG. 2 , 1st speed output gear 62 , 3rd speed output gear 64 and 5th speed output gear 66 are meshed with 1st speed input gear 58 , 3rd speed input gear 56 and 5th speed input gear 54 , respectively. Similarly, reverse output gear 68 , 2nd speed output gear 70 , and 4th speed output gear 72 are meshed with reverse input gear 52 (through idler 94 ), 2nd speed input gear 48 , and 4th speed input gear 50 , respectively. In another embodiment, transmission 24 may include a second countershaft (not shown) that includes one or more of the output gears rotatably disposed on first countershaft 44 .
[0017] To countershaft 44 there is also integrally connected a final drive pinion gear 73 that rotates together with countershaft 44 . Final drive pinion 73 is arranged perpendicular to an axis of a rotational output member 74 , such as a final drive ring gear, and is meshed with output member 74 . In the embodiment shown in FIGS. 1 and 2 , a transmission output rotation from drive pinion 73 to output member 74 is distributed to wheels 34 through a drive shaft 36 and a differential 38 .
[0018] Referring again to FIG. 2 , transmission 24 also includes axially moveable clutches 82 , 84 , 86 and 88 , such as synchronized single or double acting dog-type clutches, which are splined to countershaft 44 for rotation therewith. Clutch 82 is moveable by a conventional shift fork (not shown) in an axial direction toward main clutch assembly 28 to fix countershaft 44 for rotation with 1st speed output gear 62 . Similarly, clutch 84 may be moved in opposite axial directions to rotationally fix output gear 64 or output gear 66 to countershaft 44 . Clutch 86 may be selectively moved in opposite axial directions to rotationally fix output gear 68 or output gear 70 to countershaft 44 . Clutch 88 may be moved in an axial direction toward main clutch assembly 28 to fix countershaft 44 for rotation with output gear 72 . In another embodiment, clutches 82 , 84 , 86 and 88 may also be provided on first and second input shafts 40 , 42 to engage and disengage gears rotatably supported on input shafts 40 , 42 in a manner substantially similar to the manner in which the gears are engaged on countershaft 44 .
[0019] In an embodiment, the transmission 24 also includes axially moveable input shaft clutches 90 and 92 , such as synchronized single acting dog-type clutches, which are splined to first input shaft 40 for rotation therewith. In the illustrated embodiment, clutch 90 may be moved in an axial direction toward main clutch assembly 28 to fix first input shaft 40 for rotation with second input shaft 42 . Similarly, clutch 92 may be moved in an axial direction away from main clutch assembly 28 to fix first input shaft 40 for rotation with output member 74 .
[0020] As described above, ECU 30 delivers commands to the components of powertrain system 20 based on the receipt and evaluation of various input signals. These commands may include gear ratio interchange commands to a shift control device that indirectly moves clutches 82 , 84 , 86 , 88 , 90 and 92 to establish the gear ratios between first and second input shafts 40 , 42 and countershaft 44 . The shift control system 26 may be a conventional device, or any other suitable device that controls the axial position of each of clutches 82 , 84 , 86 , 88 , 90 and 92 .
[0021] Operation of hybrid powertrain system 20 will now be described with reference to FIG. 2 . In a first mode of operation employed during vehicle launch and acceleration, first and second main clutches C 1 and C 2 are initially disengaged and clutch 82 is moved leftward from the neutral position shown in FIG. 2 , so that 1st speed output gear 62 is fixed to countershaft 44 by clutch 82 . Upon this movement, power from prime mover 22 may be transmitted to countershaft 44 by engaging second main clutch C 2 . The power applied to second input shaft 42 is transmitted through 1st speed input gear 58 to countershaft 44 through 1st speed output gear 62 , and then to final drive pinion 73 so that a first speed ratio is established in transmission 24 .
[0022] As the vehicle accelerates and the second speed ratio is desired, clutch 86 is moved rightward from the neutral position shown in FIG. 2 , so that 2nd speed output gear 70 is fixed to countershaft 44 by clutch 86 . The engagement of clutch 86 occurs while first main clutch C 1 is disengaged and no power is being transmitted from prime mover 22 to first input shaft 40 . Once clutch 86 is engaged, the currently engaged second main clutch C 2 is disengaged while simultaneously or nearly simultaneously engaging first main clutch C 1 . The resulting power applied to first input shaft 40 is transmitted through 2nd speed input gear 48 to countershaft 44 through 2nd speed output gear 70 , and then to final drive pinion 73 so that a second speed ratio is established in transmission 24 . This process is repeated, including the selective activation of the appropriate clutch, in the same manner for up-shifting through the remaining gear ratios, and in a reverse manner for down-shifting from one gear ratio to another.
[0023] To achieve the reverse gear in transmission 24 , first and second main clutches C 1 and C 2 are disengaged and clutch 86 is moved leftward from the neutral position shown in FIG. 2 , so that reverse output gear 68 is fixed to countershaft 44 by clutch 86 . The power applied to first input shaft 40 is transmitted from reverse input gear 52 to countershaft 44 through an idler gear 94 and reverse output gear 68 , and then to final drive pinion 73 .
[0024] Under a normal operating state, wherein transmission 24 assumes a certain speed gearing, both first and second main clutches C 1 and C 2 may be kept in their engaged conditions while one of clutches 82 , 84 , 86 , and 88 is kept at a given power transmitting position. For example, when transmission 24 assumes the 5th speed ratio, both first and second main clutches C 1 and C 2 may be engaged while clutch 84 is engaged with 5th speed output gear 66 and clutches 82 , 86 and 88 are in their neutral position shown in FIG. 2 . Although first and second main clutches are engaged, no power is transmitted through the unselected output gears 62 , 64 , 68 , 70 and 72 because the output gears are free to rotate on countershaft 44 when not engaged by a corresponding clutch 82 , 86 or 88 .
[0025] In the embodiment shown in FIG. 2 , gears 58 and 62 establish a “low” gear ratio between second input shaft 42 and countershaft 44 when clutch 82 fixes gear 62 for rotation with countershaft 44 . Gears 54 and 66 establish a “high” gear ratio between second input shaft 42 and countershaft 44 when clutch 84 fixes gear 66 for rotation with countershaft 44 .
[0026] As best seen in FIG. 3 , the main clutch assembly 28 includes a housing 100 , a damper 102 , a clutch collar 104 , a clutch drum 106 , a first clutch hub 108 , a second clutch hub 110 , a first piston assembly 114 , and a second piston assembly 116 .
[0027] The housing 100 is connected to a portion of the transmission 24 and the prime mover 22 . In the embodiment illustrated, the damper 102 is a lubricated noise, vibration and harshness (NVH) damper for reducing at least undesired drivetrain torque oscillations and other vibrations. The clutch drum 106 is coupled to an outer portion of the damper 102 for rotation therewith.
[0028] In the embodiment illustrated, the clutch drum 106 includes a plurality of annular first drum disks 122 and a plurality of annular second drum disks 124 extending radially therefrom. The first clutch hub 108 includes a plurality of annular first hub disks 128 extending radially therefrom. The second clutch hub 110 includes a plurality of annular second hub disks 130 extending radially therefrom. The first drum disks 122 are interleaved with the first hub disks 128 , and the second drum disks 124 are interleaved with the second hub disks 130 , as described in greater detail below.
[0029] FIG. 4 illustrates an enlarged portion of the main clutch assembly 28 of FIG. 3 . As best seen in FIG. 4 , the first drum disks 122 include a first pressure plate 140 , a first drum first disk 142 , a first drum second disk 144 , a first drum third disk 146 , and a first reaction plate 148 . The second drum disks 124 include a second pressure plate 150 , a second drum first disk 152 , a second drum second disk 154 , a second drum third disk 156 , and a second reaction plate 158 . The first hub disks 128 include a first hub first disk 162 , a first hub second disk 164 , a first hub third disk 166 , and a first hub fourth disk 168 . The second hub disks 130 include a second hub first disk 172 , a second hub second disk 174 , a second hub third disk 176 , and a second hub fourth disk 178 .
[0030] The first pressure plate 140 includes a first pressure plate forward surface 180 and a first pressure plate rearward surface 182 . The first drum first disk 142 includes a first drum first disk forward surface 184 and a first drum first disk rearward surface 186 . The first drum second disk 144 includes a first drum second disk forward surface 188 and a first drum second disk rearward surface 190 . The first drum third disk 146 includes a first drum third disk forward surface 192 and a first drum third disk rearward surface 194 . The first reaction plate 148 includes a first reaction plate forward surface 196 and a first reaction plate rearward surface 198 .
[0031] The second pressure plate 150 includes a second pressure plate forward surface 200 and a second pressure plate rearward surface 202 . The second drum first disk 152 includes a second drum first disk forward surface 204 and a second drum first disk rearward surface 206 . The second drum second disk 154 includes a second drum second disk forward surface 208 and a second drum second disk rearward surface 210 . The second drum third disk 156 includes a second drum third disk forward surface 212 and a second drum third disk rearward surface 214 . The second reaction plate 158 includes a second reaction plate forward surface 216 and a second reaction plate rearward surface 218 .
[0032] The first hub first disk 162 includes a first hub first disk forward surface 220 and a first hub first disk rearward surface 222 . The first hub second disk 164 includes a first hub second disk forward surface 224 and a first hub second disk rearward surface 226 . The first hub third disk 166 includes a first hub third disk forward surface 228 and a first hub third disk rearward surface 230 . The first hub fourth disk 168 includes a first hub fourth disk forward surface 232 and a first hub fourth disk rearward surface 234 .
[0033] The second hub first disk 172 includes a second hub first disk forward surface 240 and a second hub first disk rearward surface 242 . The second hub second disk 174 includes a second hub second disk forward surface 244 and a second hub second disk rearward surface 246 . The second hub third disk 176 includes a second hub third disk forward surface 248 and a second hub third disk rearward surface 250 . The second hub fourth disk 178 includes a second hub fourth disk forward surface 252 and a second hub fourth disk rearward surface 254 .
[0034] The first piston assembly 114 includes an annular first apply plate 260 , an annular first piston 262 , an annular first return spring 264 . The first piston 262 includes a first piston reaction surface 266 and a first piston apply surface 268 . The second piston assembly 116 includes an annular second apply plate 270 , an annular second piston 272 , an annular second return spring 274 . The second piston 272 includes a second piston reaction surface 276 and a second piston apply surface 278 . The clutch drum 106 , the first apply plate 260 and the first piston 262 define an annular first piston chamber 280 . The clutch drum 106 , the second apply plate 270 and the second piston 272 define an annular second piston chamber 282 . The first piston assembly 114 and the second piston assembly 116 include annular piston seals 290 for sealing the piston chambers 280 , 282 . In the embodiment illustrated, the first return spring 264 is axially restrained by a first piston retaining ring 292 and a first drum retaining ring 294 . The second return spring 274 is axially restrained by a second piston retaining ring 296 and a second drum retaining ring 298 .
[0035] In the embodiment illustrated, the piston seals 290 are constructed of a material that will withstand heated fluid from the clutch disks 122 , 124 , 128 , 130 , such as DuPont™ Vamac®, or other suitable material.
[0036] The clutch collar 104 supplies fluid to the clutch drum 106 , which supplies fluid to the first piston assembly 114 , the second piston assembly 116 , and the clutch disks as discussed in greater detail below. The clutch drum 106 includes a first piston chamber port 300 , and a second piston chamber port 302 . The shafts 40 , 42 define a first clutch cooling port 304 and a second clutch cooling port 306 . The clutch collar 104 is adapted to supply a cooling fluid (not shown) to the ports 300 , 302 and control the pressure thereof, as is conventionally known.
[0037] The clutch drum 106 is further defined by a central web 310 , an annular first balance chamber wall 312 , a cylindrical first balance chamber connecting wall 314 , a second balance chamber wall 316 , and a cylindrical second balance chamber connecting wall 318 . The first piston 262 , the first balance chamber wall 312 , and the first balance chamber connecting wall 314 define a first balance chamber 320 . The clutch drum 106 is also defined by a first coolant passage 322 , a first reservoir 324 , a first cooling first inlet 326 , a first cooling second inlet 328 , a first cooling third inlet 330 , and a first cooling fourth inlet 332 . The second piston 272 , the second balance chamber wall 316 , and the second balance chamber connecting wall 318 define a second balance chamber 340 .
[0038] As the main clutch assembly 28 rotates about the axis A-A ( FIG. 3 ), fluid supplied through the ports 300 , 302 , 304 , 306 will tend to rotate with the main clutch assembly 28 and will be accelerated away from the axis A-A. As fluid present within the first piston chamber 280 and the second piston chamber 282 is accelerated away from the axis A-A, the fluid will bias the respective piston 262 , 272 away from the respective apply plate 260 , 270 and act against the biasing force of springs 264 , 274 . Additionally, the fluid supplied through the ports 304 , 306 will cool the clutch disks 122 , 124 then fill the balance chambers 320 , 340 .
[0039] When fluid pressure is supplied through the first piston chamber port 300 , the first piston 262 will move in the rearward direction (illustrated as the arrow R in FIGS. 3 and 4 ) as the first apply plate 260 remains generally stationary relative to the clutch hub 106 . The first return spring 264 is axially deflected due to interference between the first piston retaining ring 292 and the first hub retaining ring 294 as the first piston 262 moves in the direction R, biasing the first piston in the direction of arrow F. As the first piston 262 moves in the direction R, the first piston will move toward the first balance chamber wall 312 and reduce the volume of fluid within the first balance chamber 320 . Generally, the volume of fluid that is forced into the first piston chamber 280 is equal to the volume of fluid that is displaced from the first balance chamber 320 , thereby maintaining the rotational weight and the rotational inertia of the main clutch assembly 28 .
[0040] As the first piston 262 moves in the direction of the arrow, the first piston reaction surface 266 urges the first pressure plate 140 toward the first reaction plate 148 , thereby actuating the first clutch C 1 . While the first clutch C 1 and the second clutch C 2 are illustrated as a clutch pack having interleaved disks, the clutches used in the main clutch assembly may be any clutch configuration, having any number of engaging frictional surfaces.
[0041] By providing components of the main clutch assembly 28 , such as the clutch disks 122 , 124 , 128 , 130 interposed radially within the piston assemblies 114 , 116 , the resulting clutch assembly may have a desirably shorter axial length when compared to clutch assemblies that have components orientated solely in an axial orientation. Generally, the weight of the clutch disks 122 , 124 , 128 , 130 is greater than the weight of the piston assemblies 114 , 116 . Accordingly, positioning the clutch disks 122 , 124 radially inward of the piston assemblies 114 , 116 will result in a main clutch assembly 28 with a lower rotational inertia when compared to a clutch assembly having clutch packs positioned radially outward of piston assemblies. In the embodiment illustrated, the clutch disks 122 , 124 , 128 , 130 are axially adjacent with a minimum number of clutch components positioned between the clutch disks 122 , 124 , 128 , 130 and the shafts 40 , 42 to further decrease the rotational inertia of the main clutch assembly 28 .
[0042] The preceding description has been presented only to illustrate and describe exemplary embodiments of the methods and systems of the present invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims. | A clutch apparatus includes a clutch pack having a plurality of friction disks. The clutch pack will selectively transfer torque from a torque supplying member to a first torque receiving member. The apparatus also includes a first piston chamber positioned radially outward of the clutch pack. The first piston chamber is operably connected to the clutch pack for exerting a compressive force on at least a portion of the clutch pack as a first fluid is pressurized into the first piston chamber. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a coolant purification system and more particularly to an improved apparatus for removing foreign particles from the cooling and lubricating fluid used in machining operations.
In many types of machine operations, a coolant is supplied to the area being machined for a number of purposes. One of these purposes is to cool and lubricate the machining operation. The other and equally important purpose is to remove the machined particles as well as other foreign matter from the area where machining is occurring so as to improve surface finish.
Although in principle this appears to be simple and obvious, accomplishing these results and being able to operate the equipment over long periods without servicing presents substantial considerations. Environmental concerns also require the reclaiming of the coolant and lubricant and recirculation of it, and this adds greatly to the aforenoted problems.
In some ways, this invention relates to an improvement or an alternative arrangement for providing coolant purification to that shown in my copending United States Letters Patent of the same title, Ser. No. 09/063,017 filed Apr. 20, 1998, now U.S. Pat. No. 6,015,487, and assigned to the assignee hereof.
A prior art type of apparatus is illustrated in FIG. 1 and the effectiveness of various types of prior filtering materials utilized for coolant purification is shown in FIGS. 2 and 3. The apparatus shown in FIG. 1 includes a machining station 21 having a cutting tool 22 that operates to machine the surfaces of a work piece 23 . In the illustrated embodiment, by way of example, the cutting tool 22 is a grinding wheel and the work piece 23 is a gear blank onto which gear teeth are formed by the grinding operation.
This grinding operation takes place over a catch tank 24 with a coolant supply nozzle 25 being provided so as to spray the cooling liquid to the machined area. This liquid is then collected in the catch tank 24 and is returned to a purification apparatus, indicated generally by the reference numeral 26 , where the cutting liquid is collected in a storage tank 27 . A pump 28 draws the coolant from the storage tank 27 and delivers it via the nozzle 28 to the machine area.
In the specific prior art example shown, the purification apparatus 26 comprises a centrifugal separator including an impeller element 29 that is driven by an electric motor 31 and which separates foreign particles from the coolant in a manner known. The purified coolant is returned to the storage tank 27 through a purification return line 32 .
FIG. 2 shows the typical efficiency of this type of centrifugal apparatus by indicating the NAS value. This NAS value is a standard by which the number and size of entrain particles captured by the filter are measured. On the absissa, the size of particles is shown, while on the ordinate, the NAS number is indicated.
It will be seen that the centrifugal type separator is fairly consistent in the NAS number of the particles of varying sizes, but nevertheless does not exclude as many particles as desired, particularly those in the larger sizes, such as 50-100 μm. Thus its efficiency is not great.
Another type of filter which may be employed for purifying coolant and which has a higher filtration efficiency is the diatomaceous earth type. FIG. 3 shows the efficiency of this type of filter.
As may be seen in this figure, the efficiency is higher, particularly with larger size particles. However, this type of filter requires frequent servicing and hence is expensive to operate and does not afford long operational cycles between servicing. Also, the smaller size particles are more difficult to capture with this type of filter if reasonable flow velocities and small size of the filter are obtained.
Therefore, it is a principle object of this invention to provide an improved coolant purification system usable with machining operations that will remove with high efficiencies particles of a variety of sizes and which can be operated for long time intervals without necessitating servicing.
It is a principle object, therefore, to provide an improved coolant purification system for a machining apparatus that has high efficiency and long service life while permitting operation at lower cost.
SUMMARY OF THE INVENTION
In accordance with this invention, there is provided a coolant purification system for machining operation that includes a system for supplying coolant to the machined area and collecting the utilized coolant and purifying it. The purification apparatus includes at least a rare earth magnetic separator, bag filters, and a deep level filter that are disposed in a flow path along a coolant circulation arrangement and for returning the coolant to a storage tank for recirculation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a prior art type of coolant purification system employing primarily a centrifugal separator.
FIG. 2 is a graphical view showing the efficiency of the centrifugal separator.
FIG. 3 is a graphical view showing the efficiency of a diatomaceous earth type purifier.
FIG. 4 is a schematic view in part similar to FIG. 1, but showing an embodiment of the invention.
FIG. 5 is a partial cross-sectional view showing one embodiment of return arrangement to the main coolant storage tank.
FIG. 6 is a cross-sectional view, in part similar to FIG. 5, and shows another arrangement for returning coolant to the main storage tank.
FIG. 7 is a cross-sectional view showing how the Q-pot works.
FIG. 8 is a top plan view showing the relationship of the fluid return and its cooperation with the Q-pot to improve efficiency.
FIG. 9 is a cross-sectional view, in part similar to FIG. 8 showing another embodiment of fluid return to the Q-pot for improving efficiency.
FIG. 10 is a cross-sectional view, in part similar to FIGS. 8 and 9, and shows yet another arrangement for returning fluid and improving the efficiency.
FIG. 11 is a perspective view showing an arrangement for a secondary storage tank for achieving centrifugal separation.
FIG. 12 is a schematic view showing the construction of the mechanical type filter arrangement including the bag and deep level filter arrangement of the construction shown only generally in FIG. 4 .
FIG. 13 is a cross-sectional view showing another arrangement for returning fluid and removed particles to the main storage tank.
FIG. 14 is an efficiency curve showing the efficiency of the rare earth magnetic separator of this embodiment.
FIG. 15 is a graphical view showing how the relationship between the roller gap and the magnetic particle capture rate at varying flow quantities is effective in improving the service life of the magnetic type separator.
FIG. 16 is a graphical view showing the efficiency of the coolant purification degree through the bag filters.
FIG. 17 is a graphical view showing the filtration efficiency or coolant purification degree of the deep level type filter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail initially to FIG. 4, this figure shows a coolant purification system embodying the invention in conjunction with a machining apparatus which basically has the same general layout as a prior art type of apparatus and which, therefore, has been indicated by the same reference numerals applied in the description of prior art FIG. 1 . Thus, this apparatus includes the machining section 21 wherein the grinding wheel 22 grinds the finished form on the gear blank 23 . The coolant is supplied to the machining area by a spray nozzle 25 from the purification system.
This purification system includes a main coolant storage and collection tank 51 . Coolant is delivered from the drain or collection tray 24 to this storage tank 51 by means of a rare earth type magnetic separator, indicated generally by the reference numeral 52 . This separator includes a rotating magnetic drum 53 that operates to rotate through the collected fluid in a trough and remove the extracted particles through a discharge chute 54 before return of the purified coolant to the storage tank 51 through a return 55 .
The return 55 may have configurations as will be described later by reference to FIGS. 5 and 6 for controlling the flow amount and cooperates with a supply line 56 in which a pump 57 is provided. The pump 57 pumps fluid through a check valve 58 and past a control valve 59 to a mechanical filter assembly, indicated generally by the reference numeral 61 , and which has a construction that will be described later in more detail by reference to FIG. 13. A pressure gauge 60 is placed in this line 56 between the check valve 58 and the flow control valve 59 .
Air may be bleed from the mechanical filter assembly 61 , through an air bleed path 62 in which a flow control valve 63 is provided and which communicates back with the rare earth magnetic filter 52 above the coolant level therein.
Fluid flows primarily from the filter element 61 through a main supply line 64 to a coolant (heat exchanger) cooler and purifier, indicated generally by the reference numeral 65 . This type of device 65 includes a second storage tank 66 in which the fluid is contained and a suitable cooling arrangement for removing heat from the circulated coolant. This includes a circulating or agitating propeller 67 that circulates the coolant in the tank and also a sensor 68 which senses if the coolant falls to a low level to give a warning signal. An overflow line 69 permits excess coolant to flow directly back to the main storage tank 51 .
The purified and cooled coolant from the coolant device 65 is delivered to the spray nozzle 25 through a conduit 71 in which an on/off valve 72 is provided upstream of a secondary pump 73 . The pump 73 discharges into the line 71 through a check valve 74 and flow control valve 75 .
Pressure gages 76 and 77 are disposed between the check valve 74 and the flow control valve 75 and downstream of the control valve 75 , respectively. The conduit 71 then discharges directly to the spray nozzle 25 for delivering the coolant to the machining area.
Coolant from the filter 61 also may be returned to the main storage tank for cleaning purposes past the cooling device 65 through a drain return line 78 . This will be described in more detail later. The drain return line 78 communicates with the lower level of the main storage tank 51 through an on/off valve 79 or in another manner to be described by reference to FIG. 13 .
Coolant for flushing the catch tray 24 is also drawn from the tank 51 through a conduit 81 and delivered to a pair of spray nozzles 82 and 83 . A main shut off valve 84 connects the main storage tank 51 to a high pressure pump 85 that discharges into the conduit 81 . A check valve 86 and flow control valve 87 are provided in the line 81 with a pressure gauge 88 being disposed therebetween. The line 81 branches into two lines, each connected to a respective one of the spray nozzles 82 and 83 . On/off valves 89 and 91 control the communication with the spray nozzles 82 and 83 . These nozzles may be employed for flushing additional coolant into the catch tray 24 and returning it back to the rare earth magnetic filter 52 to remove accumulated particles even when no machining operation is being performed.
Finally, the main system also includes a Q-pot device, indicated generally by the reference numeral 92 , which has a construction as will be described later by reference to FIG. 7 that serves the purpose of removing floating particles from the coolant and separating them. This Q-pot 92 has a pick up device that communicates with a further conduit 93 in which a pump 94 is provided. The pump 94 has the capability of supplying fluid to a further spray nozzle 95 through a line in which an on/off valve 96 is provided. A priming funnel 97 and on/off valve 98 is provided in the line 99 that extends to the spray nozzle 95 so as to start up this system if desired. This system can be used fir flushing the catch tray 24 as well as preventing these particles from entering the machining area.
Thus, on the basic principle of operation, the coolant is filtered first by the rare metal magnetic filter 52 , floating impurities are removed by the Q-pot 92 and the fluid is filtered by the deep filter and bag filters in the filter unit 61 . Then, the fluid may be passed through the cooler 65 for recirculation.
Embodiments of desirable ways in which the fluid is returned at controlled rates from the rare earth magnetic separator 52 to the main storage tank 51 will be described by reference to FIGS. 5 and 6. In the first of these embodiments, the main storage tank discharge 55 functions as a funnel formed at the bottom of a body assembly 101 of the separator 52 .
This funnel 55 discharges to a further funnel 102 that is fixed to the lower wall of the main storage tank 51 and which is connected to the line 56 in which a main shut off valve 103 is provided. The opening of this funnel arrangement and the cooperation with the pump 57 is such that the pump 52 pumps a flow quantity Q 2 which is larger than the flow quantity of fluid that enters the magnetic separator 52 (Q 1 ). That is, Q 2 is greater than Q 1 (Q 2 >Q 1 ).
A modified configuration for accomplishing this result is also shown in FIG. 6 wherein the discharge section 51 is provided with a converging nozzle portion 104 that cooperates with a further conical shaped portion 105 of the discharge portion 102 and which communicates with the line 56 . Again, the arrangement is such that the flow quantity Q 2 is greater than Q 1 (Q 2 >Q 1 ).
The structure of the Q-pot 92 will now be described by reference to FIG. 7 and later figures will describe how the fluid is returned to the main storage tank 51 so as to assist in the operation of the Q-pot by reference to FIGS. 8-11.
The Q-pot 92 is comprised of a central tube 111 that has a fitting 112 at its lower end above which is placed four, equally spaced flow openings 113 . An elastic bellows 114 , which is impervious in nature, is affixed to the end fitting 104 at its, lower end. The upper end of the bellows 114 is fixed to a ring 115 which surrounds the tube 111 but is spaced radially outwardly therefrom so as to permit a flow into this area, indicated as 117 , as shown by the arrows in FIG. 7 . Thus, any floating particles will be drawn into the bellows 114 and picked up through the openings 113 and drawn from the pick up 111 into the return lines 93 and 99 for continuous recirculation and redelivery to the rare earth magnetic separator 52 . This will assist in ensuring that these floating particles do not find their way back into the cooling fluid that is delivered by the spray nozzle 25 .
As seen in FIG. 8, the magnetic separator 52 may be provided with a discharge port 116 that flows across the upper surface of the storage tank 51 so as to provide a swirling action toward the Q-pot 92 and specifically the inlet opening 117 formed at the upper end thereof by the member 15 . This will assist in ensuring that these floating particles are skimmed off and prevented from being mixed with the coolant that is delivered by the spray nozzle 25 .
FIG. 9 shows another way in which this can be done. In this figure, there is depicted a mist acquisition device 121 that functions to collect vapors from above the collection tray 24 and deliver them through a conduit 122 across the upper surface of the main storage tank 51 . This will cause the foreign particles entrained into these vapors to flow directly toward the opening 117 of the Q-pot 92 .
Also, as shown in FIG. 10, the overflow pipe 69 from the cooler 65 may also be so directed toward the upper surface of the liquid in the main storage tank 51 so as to direct the floating particles toward the opening 117 of the Q-pot 92 .
FIG. 11 shows another arrangement for assisting in the centrifugal separation of solid particles from the coolant that is delivered to the cooler 65 . In fact, this shows more detail of the structure shown in FIG. 4 wherein the return conduit 64 mates with a manifold 123 which, in turn, has four depending pipe sections 124 at the four corners of the rectangular container and which have discharge nozzles so as to give a circumferential swirl to the fluid so as to provide centrifugal separation to a conical shape lower area for separation and draining periodically. The heavier particles will be thrown outwardly by the centrifugal action and then collected by gravity to the lower part of the conical section for periodic removal. This will reduce the frequency at which the tank 66 of the cooler need be cleaned.
The construction of the main mechanical filter assembly 61 will now be described in initial detail by primary reference to FIG. 12 . As seen in this figure, and as previously described, the line 56 enters the filter assembly 61 . This communicates with a main distribution line 131 which discharges to bag-type filters 132 a , 132 b and 132 c that are disposed in parallel flow fashion, each having a respective inlet 133 from the line 131 .
Each bag filter 132 is formed with a bag-like configuration having a woven or non-woven cloth made of a synthetic fiber and which may have meshes that are either the same size or in different sizes. However, the preference is to use a smaller number of bag filters with course meshes, particularly where the machining operation is such so as to not provide long length chips. In a preferred embodiment, the three bag filters 132 a, b and c , have a mesh of approximately 40 μm.
The bag filters 132 all have respective discharges 134 a, b and c that communicate with respective manifold lines 135 a , 135 b and 135 c , respectively. These manifold lines extend at one end thereof to a main filter conduit 136 which, in turn, communicates with a deep filter element 137 through a line in which a main shut off valve 138 is provided.
The deep level filter 137 is formed from a lamination with woven or non-woven cloth of synthetic fibers with course cylindrical outer layers and progressively finer cylindrical inner layers. Thus, the larger particles will be accumulated in the external portion of this filter, and the smaller particles will be in the inner portion. However, by using a large number of small diameter cylinders, each having respective meshes, it is possible to contain the filter in a small volume and permit replacement of the cylinders, either as a group or individually. It is has been found that by utilizing filter meshes of 15 μm, it is possible to obtain a level of purification similar to that of a diamatatious earth filter.
A pressure gauge 139 and pressure sensors 141 are associated with the inlet to the deep level filter 137 and in a like manner, pressure gauges 142 are associated with each of the bag-type filters 132 with a pressure sensor 143 being connected to one of them.
A shut off valve 144 is provided at the outlet from the deep level filter 138 to the line 78 connecting the filter back to the cooler 65 .
In addition, a clean out line 145 is associated with the deep level filter 137 for its cleaning purposes and this line has in it a main shut off valve 146 , pressure gauge 147 and pressure sensor 148 . This line can either be connected back to the return 64 or can be opened for drain purposes through a drain valve 149 . The bag-type filters 132 a , 132 b and 132 c may also be cleaned by opening a clean out line valve 151 which dumps the fluid through a diffuser 152 from a line 153 that parallels the line 136 .
The diffusion 152 is shown in more detail in FIG. 13 and communicates with the main storage tank 51 . This diffusion 152 is coupled by a coupling 155 to the line 153 and has an elbow fitting 156 with discharge openings 157 spaced therearound. These are formed in a plug-like member 158 so that the discharge can be returned to the tank 51 through an upper surface thereof so that any floating materials cleaned can be removed by the Q-pot 92 .
If it is desired to run the system without utilizing the filter 61 , it can be bypassed by means of a bypass line, indicated by the reference numeral 159 in FIG. 12 in which a shut off valve 161 is provided. If the filters are to be bypassed the shut off valve 161 is opened and the valves 161 and a further valve 162 in a bypass line 163 between the manifold branch 136 and the return line 145 is closed. At this time, the valve 146 should also be closed.
By utilizing the filters in the arrangement described, it is possible to obtain very high degrees of filtration and, at the same time, minimize the necessity for servicing the individual elements of the filtration system. This may be understood best by reference to FIGS. 14-17.
FIG. 14 shows the efficiency NAS of the rare earth magnetic separator 52 . As may be seen, this picks out the larger particles and thus removes them before passing through the finer filters. Of course, the purification range is in the range of 12 to 16 NAS and hence very small particles are not removed in this portion of the system.
FIG. 15 shows the efficiency of the rare earth magnetic filter and how its capture rate raises in inverse proportion to the flow velocity. Also, the magnetic force by the magnet raises in inverse proportion to the square of the distance between the magnet and the particles.
The family of curves shown in this figure indicate the efficiencies with respect to these two characteristics. The spacing is indicated on the absessa, while the efficiency is indicated on the ordinant. Thus by using a high flow velocity of 240 liters per minute and a gap of five millimeters, it is possible to remove 90% of the larger particles, as well as particles which may be large but have low density. By utilizing this arrangement, the lives of the bag filters 132 and the deep level filter 137 can be prolonged considerably, for example, to two to six months in each case. Thus, this system provides very good filtration as well as long life.
FIG. 16 shows the purification ability of the bag filters 132 . As may be seen, they are particularly efficient in removing particles of the size of 50 μm or larger and even have a good efficiency on smaller size particles. Also, because of the high efficiency of the bag filters even with very small particles, this means that the deep filter 137 can be operated for long periods without servicing, even though it is removing extremely small particles.
The efficiency of this deep level filter is shown in FIG. 17 and it will be seen that it is extremely efficient and thus coupled with the efficiencies of the other filters provides not only good filtration capability but very long life without servicing.
There is also provided an arrangement that facilitates cleaning of the bag filters 132 . Because of their nature, the grinding chips and cuttings will collect on the inner surface of the bag filters and form a cake which may get to 10 mm thick or even thicker. This makes it very difficult to drain the filters and also to clean them. Thus, in order to provide cleaning and breaking up of these congealed deposits, a cleaning system is incorporated that will be described by reference to FIG. 12 .
In order to provide this cleaning, the on/off valve 138 on the discharge side of the system is closed and the valve 151 is opened. In addition, there is provided a high pressure air source such as a factory air line, indicated at 164 in FIGS. 2 and 12 that communicates with the inlet sides of these bag filters through a conduit 165 . Shut off valves 166 and 167 are provided in the line 166 as well as an oil separator 167 that separates any oil from the high pressure air line.
When the pressure is exerted and the residue is broken up, it will then be forced out of the discharge lines 134 a , 134 b and 134 c and into the discharge line 153 . By opening the valve 151 , the diffuser nozzle 152 can deliver the sediment particles back to the storage tank 51 where they can be easily removed. The diffuser 152 will provide a collecting function to avoid disbursement of these particles and facilitate their collection.
Thus, from the foregoing description, it should be readily apparent that the described construction provides a very effective filtration system that will filter coolant for machining operations and which will operate for long time periods with minimum servicing and with minimum diminution of efficiency. Of course, the foregoing description is that of preferred embodiments of the invention and various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims. | A coolant purification system for purifying and removing particles from the coolant used in machining operations. The system uses a rare earth magnetic separator in combination with bag-type filters and deep level filters that are arranged in sequences so that the filters that tend to clog more frequently due to the removal of small particles will not be clogged by particles that are easily removed by coarser filters of this system. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a non provisional patent application of US Provisional Patent Application Ser. No. 61/578,830, filed 21 Dec. 2011.
[0002] Priority of U.S. Provisional Patent Application Ser. No. 61/578,830, filed 21 Dec. 2011, hereby incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0004] Not applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to cargo racks for transferring goods between marine vessels and offshore platforms such as oil and gas well drilling and production platforms. More particularly, the present invention relates to an improved cargo rack that enables a user to load the rack with multiple load modules (e.g. fluid containing vessels or tanks), palletized loads, bulk bags (or other loads) and to then transport the entire rack using a lifting device such as a crane or a forklift from one locale (e.g. marine vessel) to another locale (e.g. marine platform). Additionally, the entire rack can be moved on land or on the platform with a crane or forklift. When supporting fluid holding vessels or tanks, a specially configured manifold can be used to empty a particular or selected tank or vessel. Lifting fittings are placed at the top of intermediate columns and inner reinforcement members (e.g. inner braces or walls) transfer load from one intermediate column to another intermediate column.
[0007] 2. General Background
[0008] In the exploration of oil and gas in a marine environment, fixed, semi submersible, jack up, and other offshore marine platforms are used during drilling operations. Fixed platforms are typically used for production of oil and gas from wells after they have been drilled. Drilling and production require that an enormous amount of supplies be transported from land based storage facilities. Supplies are typically transferred to offshore platforms using very large marine vessels called work boats. These work boats can be in excess of one hundred feet (30.48 meters) in length and have expansive deck areas for carrying cargo that is destined for an offshore platform. Supplies are typically transferred from a land based dock area to the marine vessel using a lifting device such as a crane or a mobile lifting and transport device such as a forklift.
[0009] Once a work boat arrives at a selected offshore platform, supplies or products are typically transferred from the deck of the work boat to the platform using a lifting device such as a crane.
[0010] Once on the deck of a drilling platform or production platform, space is at a premium. The storage of supplies on an offshore oil well drilling or production platform is a huge problem.
[0011] Many cargo transport and lifting devices have been patented. The table below lists some patents that relate generally to pallets, palletized racks, and other cargo racks.
[0000]
TABLE 1
ISSUE DATE
PAT. NO.
TITLE
(MM/DD/YYYY)
2,579,655
Collapsible Container
12-25-1951
2,683,010
Pallet and Spacer
07-06-1954
3,776,435
Pallet
12-04-1973
3,916,803
Loading Platform
11-04-1975
4,165,806
Palletizing System for Produce Cartons
08-28-1979
and the Like
4,403,556
Drum Retainer
09-13-1983
4,828,311
Metal Form Pallet
05-09-1989
5,078,415
Mobile Carrier for Gas Cylinders
11-07-1992
5,156,233
Safety Anchor for Use with Slotted Beams
10-20-1992
5,292,012
Tank Handling and Protection Structure
03-08-1994
5,507,237
Lifting Apparatus for Use with Bulk Bags
04-16-1996
5,906,165
Stackable Tray for Plants
05-25-1999
6,058,852
Equipment Skid
05-09-2000
6,357,365
Intermediate Bulk Container Lifting Rack
03-19-2002
6,371,299
Crate Assembly and Improved Method
04-16-2002
6,422,405
Adjustable Dunnage Rack
07-23-2002
6,668,735
Pallet with a Plastic Platform
12-30-2003
6,725,783
Pallet for Stacking Planographic Printing
04-27-2004
Plates Thereon
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention provides a cargo rack having a frame with front, rear, and upper and lower end portions.
[0013] The lower end portion of the frame provides a base with a floor providing multiple load holding positions, each configured to hold a separate load module.
[0014] A plurality of load modules are supported with the frame during use.
[0015] The frame includes a plurality of side walls that attach to and extend upwardly from the perimeter beam base and including at least left and right side walls, the frame having four corners with a corner column at each corner.
[0016] At least one intermediate column is positioned in between two corner columns.
[0017] A plurality of gates are movably mounted to the frame, including a pair of gates at the front and a pair of gates at the rear of the frame, each gate being movably mounted to the frame between open and closed positions, each gate spanning in a horizontal direction from a corner column to an intermediate column.
[0018] A plurality of lifting eyes are attached to the upper end port of the frame, each lifting eye attached to the frame next to an intermediate column.
[0019] Inner walls or braces separate the base into the load holding positions, the inner walls spanning between intermediate columns to define a transverse support that is generally aligned with a pair of lifting eyes.
[0020] In one embodiment, there are four load holding positions.
[0021] In one embodiment, there are a pair of gates at the front of the frame.
[0022] In one embodiment, there are a pair of gates at the rear of the frame.
[0023] In one embodiment, at least a part of the floor is inclined.
[0024] In one embodiment, the floor attaches to an upper end portion of the perimeter beam.
[0025] In one embodiment, there is a drain opening in the floor.
[0026] In one embodiment, the floor attaches to an upper end portion of the perimeter beam.
[0027] In one embodiment, clamps are movably attached to the upper end of the frame between clamping and release positions for restraining vertical movement of a load that is placed on the floor.
[0028] In one embodiment, raised portions extend above the raised floor for providing a level surface to engage a load placed on a load holding position of the frame.
[0029] In one embodiment, the cargo rack provides a frame having a perimeter, a front, a rear, and upper and lower end portions.
[0030] The frame includes a plurality of side walls extending upwardly from the frame perimeter and including at least left and right side walls, four corners that each provide a corner column and an intermediate column at the front and rear of the frame in between the corner columns.
[0031] A plurality of gates are movably mounted to the frame, including a pair of gates at the front of the frame and a pair of gates at the rear of the frame, each gate being movable between open and closed positions, each gate extending between a corner column and an intermediate column.
[0032] The frame has a raised floor that provides a plurality of load holding positions.
[0033] Another embodiment provides a cargo rack having a frame with a floor, a front, a rear and upper and lower end portions.
[0034] A plurality of load modules are supported within the frame and upon the floor during use.
[0035] The frame includes a plurality of side walls extending upwardly from the perimeter beam and including at least left and right side walls, the frame having four corners and a corner column at each corner.
[0036] A plurality of gates are movably mounted on the frame, including a pair of gates at the front of the frame and a pair of gates at the rear of the frame, each gate being movable between open and closed positions, the gates enabling the load modules to be loaded laterally to the floor by accessing either the front or the rear of the frame.
[0037] The frame has positioning beams that segment the floor into a plurality of load holding positions, each having positioning beams that laterally hold one of the load modules in position once a load module is placed on the floor and in a load holding position.
[0038] The gates expose a majority of the width of the floor for loading a tank to a selected load holding position on the floor, either at the front or at the rear of the frame when the gates are opened.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0040] FIG. 1 is an elevation view of a preferred embodiment of the apparatus of the present invention;
[0041] FIG. 2 is a top, plan view of a preferred embodiment of the apparatus of the present invention taken along lines 2 - 2 of FIG. 1 ;
[0042] FIG. 3 is an end view of a preferred embodiment of the apparatus of the present invention taken along lines 3 - 3 of FIG. 2 ;
[0043] FIG. 4 is an end view of a preferred embodiment of the apparatus of the present invention, taken along lines 4 - 4 of FIG. 2 ;
[0044] FIG. 5 is a sectional view taken along lines 5 - 5 of FIG. 1 ;
[0045] FIG. 6 is a sectional view of a preferred embodiment of the apparatus of the present invention, taken along lines 6 - 6 of FIG. 1 ;
[0046] FIG. 7 is a sectional view of a preferred embodiment of the apparatus of the present invention, taken along lines 7 - 7 of FIG. 2 ;
[0047] FIG. 8 is a fragmentary view of a preferred embodiment of the apparatus of the present invention;
[0048] FIG. 9 is an end view of a preferred embodiment of the apparatus of the present invention;
[0049] FIG. 10 is a fragmentary view of a preferred embodiment of the apparatus of the present invention;
[0050] FIG. 11 is a perspective view of a preferred embodiment of the apparatus of the present invention;
[0051] FIG. 12 is a fragmentary perspective view of a preferred embodiment of the apparatus of the present invention;
[0052] FIG. 13 is a fragmentary perspective view;
[0053] FIG. 14 is a sectional view showing an alternate manifold arrangement;
[0054] FIG. 15 is a sectional view taken along lines 15 - 15 of FIG. 14 ;
[0055] FIG. 16 is an elevation view illustrating a stacking of two cargo racks;
[0056] FIG. 17 is a fragmentary elevation view of a preferred embodiment of the apparatus of the present invention;
[0057] FIGS. 18-23 are fragmentary views illustrating details of the gates and gate closures;
[0058] FIGS. 24A , 24 B and 25 A, 25 B are perspective views of an alternate embodiment of the apparatus of the present invention; and
[0059] FIGS. 26-71 are other photograph views of the alternate embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0060] FIGS. 1-23 show a preferred embodiment of the apparatus of the present invention designated generally by the numeral 10 . The preferred embodiment 10 provides a transportable cargo rack that is configured to hold multiple cargo modules or tanks 105 .
[0061] Cargo rack 10 provides a frame 11 having an upper end portion 12 and a lower end portion 13 . The lower end portion 13 includes a base 14 . Base 14 can provide a bottom 15 configured to rest upon an underlying support surface such as a floor 16 .
[0062] Base 14 floor 16 is divided into a number of floor segments or quadrants 17 , 18 , 19 , 20 . Each floor segment or quadrant 17 - 20 can contain a load module or tank 105 . This arrangement can be seen in FIG. 11 wherein four floor segments or quadrants 17 - 20 are provided, each being occupied by a tank or load module 105 .
[0063] Frame 11 has sidewalls or gates or doors. In a preferred embodiment, there are four doors 21 , 22 , 23 , 24 . The doors 21 - 24 are arranged in pairs. As shown in FIG. 2 , there are a pair of doors 21 , 22 at one end portion of frame 11 . There are another pair of doors 23 , 24 at the opposing end portion of the frame 11 , positioned generally opposite doors 21 , 22 as shown in FIG. 2 .
[0064] Each door 21 - 24 is movably (e.g. hingedly) attached to frame 11 . Hinges 25 , 26 , 27 , 28 are provided. The door 21 attaches to frame 11 at hinges 25 . The door 22 attaches to frame 11 at hinges 26 . Similarly, door 23 attaches to frame 11 at hinges 27 . Door 24 attaches to frame 11 at hinges 28 .
[0065] Each of the hinges 25 - 28 is attached to a corner column. There are four corner columns 29 , 30 , 31 , 32 . Frame 11 also provides a plurality of intermediate columns. There is an intermediate column in between each pair of corner columns 29 - 32 . Upper interior horizontal supports 37 - 40 form a connection between each intermediate column 33 - 36 and a central column 41 . Diagonal supports 42 - 45 are also provided, each diagonal support 42 - 45 extending between the central column 41 and an intermediate 33 - 36 (see FIGS. 7 and 9 ). Lower horizontal supports 46 , 47 , 48 , 49 are provide, each extending between the central column 41 and an intermediate column 33 - 36 . Each lower horizontal support 46 - 49 can be positioned below the diagonal supports 42 - 45 as shown in FIGS. 7 and 9 . Thus, interior walls are provided that extend between each intermediate column 33 - 36 and the central column 41 . Each wall or divider can be comprised of an upper interior horizontal support 37 - 40 , a diagonal support 42 - 45 , a lower interior horizontal support 46 - 49 and a plate section 50 - 53 .
[0066] Plate sections 50 , 51 , 52 , 53 extend between floor 16 and a lower horizontal support 46 , 47 , 48 or 49 . Each plate section 50 - 53 can have openings 120 for enabling easy cleanup or wash down. In FIG. 7 , the plate section 50 extends between floor 16 and lower horizontal support 46 . Plate section 52 extends between floor 16 and lower horizontal support 48 . Each of the plate sections 50 - 53 can be provided with openings or slots 120 that enable fluid to travel from one floor segment or quadrant 17 , 18 , 19 , 20 to another floor segment or quadrant 17 , 18 , 19 , 20 such as might occur during washing of the apparatus 10 .
[0067] Four lifting assemblies 54 , 55 , 56 , 57 are provided. Each lifting assembly (see FIGS. 12 , 13 ) is attached to an upper end portion of an intermediate column 33 , 34 , 35 , 36 . Peripheral horizontal members 58 span between each intermediate column 34 , 36 and a corner column 29 , 30 , 31 , 32 . Upper central fitting 59 can be in the form of a block that is receptive of and forms a connection (for example, welded) with central column 41 and each of the upper interior horizontal supports 37 , 38 , 39 , 40 as shown in FIGS. 2 and 7 .
[0068] In FIGS. 12 and 13 , each lifting assembly 54 , 55 , 56 , 57 provides a lifting block or body 60 . While one of the lifting assemblies 54 as shown in FIGS. 12 and 13 , it should be understood that each of the lifting assemblies 55 , 56 , 57 can be of the same configuration as shown in FIGS. 12 and 13 for the lifting assembly 54 . Lifting block or body 60 has side surfaces 61 , 62 , front surface 63 , and rear surface 64 . The lifting block or body 60 has an upper end portion 65 and a lower end portion 66 . Upper end portion 65 provides a recess or slot 67 that enables attachment of a lifting sling 80 to the block or body 60 using pin 69 as shown. Openings 68 are provided in block or body 60 extending between each side surface 61 , 62 and the recess or slot 67 . Pin 69 spans between the openings 68 when the apparatus is to be lifted using slings or lift lines 80 . Pin 69 has annular grooves 70 that each interlock with a plate 71 or 72 . Each plate 71 , 72 has an opening 73 or 74 . Similarly sized and shaped openings are provided on body or block 60 so that a bolted connection can be formed using bolt 75 and a nut 79 as shown in FIGS. 12 and 13 .
[0069] The annular grooves 70 of pin 69 register in slots 77 end plates 71 , 72 as shown in FIG. 12 . Each of the slots 77 communicates with a circular opening 76 that is slightly larger than the diameter of the pin 69 . In this fashion, the pin 69 can pass through the openings 76 of the plates 71 , 72 . The pin 69 is too large to occupy the recess or slot 77 . However, each annular groove 70 at an end portion of the pin 69 is sized and shaped to enable the pin 69 to interlock with the plates 71 , 72 . The annual grooves 70 enable this fit of pin 69 to the plate 71 or 72 at the slot 77 as shown in FIG. 13 .
[0070] A cover plate 78 can be placed over the block or body 60 , the plate 78 being receptive of the bottom 15 of another rack 10 when they are stacked upon one another as shown in FIG. 16 . A lifting line or sling 80 has an eyelet 81 which can be rigged to the pin 69 as shown in FIG. 13 . When a crane or other implement lifts upwardly on the slings 80 , each sling 80 eyelet 81 transfers load to the pin 69 and thus to the lifting assembly 54 , 55 , 56 , 57 and thus to the frame 11 . FIG. 11 illustrates a lifting implement or hook or crown block 82 that is commonly employed in combination with a lifting device such as a crane. Other lifting fitting such as a ring or shackle 83 can be employed as an interface between the slings 80 and the lifting implement 82 .
[0071] FIG. 6 illustrates a manifold or header 84 that can be used to transfer fluid from any one of the load modules or tanks 105 and a discharge or outlet fitting or coupling 91 . Header or manifold 84 is contained within base 11 interior 85 . The base 11 has a bottom panel 86 . A pair of beams or channels 87 , 88 extend through base 11 , each providing an opening or bore 89 , 90 that is receptive of a forklift tine. In this fashion, the frame 11 can be lifted using a forklift by engaging the forklift tines in the bores 89 , 90 of the beams or channels 87 , 88 .
[0072] Valve 92 having valve handle 93 can be placed immediately upstream of discharge of outlet fitting or coupling 91 . Header 84 communicates with valve 92 . A plurality of four flow lines 94 , 95 , 96 , 97 empty their contents into header 84 as shown in FIG. 6 . Each of the flow lines 94 , 95 , 96 , 97 attaches to a different one of the tanks or modules 105 . A detail of the fluid connection between a tank or module 105 and header 85 can be seen in FIG. 10 . FIG. 10 illustrates the connection of a single flow line 94 to a tank 105 . It should be understood that each of the flow lines 94 , 95 , 96 , 97 can be similarly connected to a tank or module.
[0073] Flow line 94 connects to swivel 98 . The swivel 98 connects to a riser 99 at elbow fitting 100 . Another elbow fitting 101 connects to hose section 102 . Hose section 102 is provided with a quick connect fitting 103 that forms a quick connect with a flow line 106 that exits the tank or module 105 . This connected position can be seen in FIG. 11 . In FIG. 11 , a tank discharge flow line 106 is shown which can be provided with a tank discharge valve 107 . Tank discharge flow line 106 can be provided with a quick connect that forms a connection with the quick connect fitting 103 of FIG. 10 . The swivel 98 enables movement of the quick connect fitting 103 as shown by arrows 104 in FIG. 10 .
[0074] Each corner column 29 - 32 can be provided with a stacking fitting 110 which enables one cargo rack 10 to be stacked upon another cargo tank 10 as seen in FIG. 16 . Each stacking fitting 110 can be connected to (e.g. welded) to a gusset or stiffener plate 111 . Each stacking fitting 110 provides a horizontal and preferably rectangular plate 112 and two vertical plates 113 , 114 which intersect at right angles and which extend upwardly from the periphery of plate 112 .
[0075] Module receptacles 115 are provided for supporting each corner of a tank or module 105 . Each receptacle 115 has a lower plate 116 and side, vertical plates 117 , 118 as seen in FIGS. 1-5 , 11 , and 16 . Each tank or module 105 has four feet 119 , each foot 119 registering upon a module receptacle 115 as seen in FIG. 11 .
[0076] A drain is provided for draining fluids from floor 16 such as might occur during a wash down or if there is leakage from one of the modules 105 . Drain channel 121 is mounted just under floor 16 as seen in FIGS. 7-8 . Drain channel 121 has flow bore 122 . A plurality of floor openings 123 are provided, such as one of the openings 123 under each opening 120 as shown in FIG. 8 . Drain channel inlet openings 124 are ports or openings in the channel 121 and are aligned with the floor openings 123 . Arrows 125 in FIG. 8 illustrate the flow path of fluid that drains from floor 116 to channel 121 bore 122 . Fluid received in channel 121 flows via gravity to drain pipe 126 . Pipe 126 is closed at one end portion with cap 127 . The other end portion of pipe 126 is fitted with valve 129 . In FIG. 8 , arrow 128 illustrates flow direction of fluid in pipe 126 .
[0077] FIGS. 17-23 illustrate the doors 21 - 24 and the mechanism for opening or closing a door. While doors 21 - 22 are shown in FIGS. 17-23 , the same configuration could be used for doors 23 - 24 . Each door 21 , 22 has a pair of vertical members. The door 21 has vertical members 130 , 131 . The door 22 has vertical members 132 , 133 . Horizontal members span between the vertical members of each door 21 , 22 as shown. The door 21 has horizontal members 134 that span between vertical members 130 , 131 . Similarly, horizontal members 135 span between the vertical members 132 , 133 of the door 22 . The innermost vertical members 131 , 133 are an assembly that includes vertical flanged members 140 , 141 , rods 138 , 139 , sleeves 142 , 143 and other plates and guides that will be described more fully hereinafter.
[0078] Each door 21 , 22 can be opened or closed using levers 153 , 154 which are attached to the rods 138 , 139 . Each rod 138 , 139 is mounted in a sleeve and in rod guides. The rod 138 is able to move up and down while being supported by sleeve 142 , upper rod guide 144 , lower rod guide 146 while being moved up or down with a lever 153 . In FIG. 17 there are two rods 138 associated with the door 21 . It should be understood, that the door 21 as constructed can be used when inverted such as if for replacing one of the other doors.
[0079] Similarly, the door 22 has two rods 139 , each rod having an attached lever 154 . The rod 139 is supported by upper rod guides 145 , lower rod guides 147 and sleeve 143 . Each of the rod guides 144 , 145 , 146 , 147 provides a rod opening 148 through which a rod 138 or 139 can pass. An upper plate 136 and a lower plate 149 are provided for locking a gate 21 , 22 in a closed position when a rod 138 , 139 is moved upwardly using a lever 153 or 154 . In FIG. 17 , all of the rods 138 , 139 are in an open position. FIGS. 23 and 23 illustrate a movement of lever 153 from the open position of FIG. 17 to the closed position. In FIG. 23 , the lever 153 is shown being moved to the closed position as indicated by arrows 161 , 162 .
[0080] Each of the upper and lower rod guides 144 , 147 can be in the form of a horizontal flange 150 or 151 .
[0081] The upper plate 136 has plate openings 137 . Similarly, the lower plate 149 has lower plate openings 152 .
[0082] Each lever 153 , 154 has a lever opening for enabling the lever 153 , 154 to be attached to a Tee shaped fitting 157 . The lever 153 has lever opening 155 . The lever 154 has lever opening 156 . Each of the Tee fittings 157 is mounted to a vertical plate. For the door 21 , the plate 158 carries two such Tee fittings 157 as shown in FIGS. 17-23 . Similarly, for the door 22 , the plate 159 carries two of the Tee fittings 157 . For each door 21 , 22 there are a pair of the plates 158 or 159 as shown in FIG. 17 .
[0083] In order to lock the gate 21 or 22 , the levers 153 or 154 move toward the upper plate 136 for the upper rods or toward the lower plate 149 for the lower rods. When the levers 153 or 154 are moved to the locking Tee fitting 163 as shown in FIGS. 23 and 23 , the rods automatically interlock with the openings 137 of the upper plate or the openings 152 of the lower plate. The rods also pass through the rod openings 148 of the upper and lower rod guides 144 - 147 .
[0084] FIGS. 24A , 24 B, 25 A, 25 B, and 26 - 71 show an alternate embodiment of the apparatus of the present invention which is designated generally by the numeral 170 . As with the preferred embodiment of FIGS. 1-23 , the alternate embodiment of the cargo rack 170 provides a frame 171 . The rack 170 is adapt to carry a plurality of modules or tanks 105 at the different floor segments or quadrants 17 , 18 , 19 , 20 . As with the preferred embodiment, there are provided four gates or doors 21 , 22 , 23 , 24 . The alternate embodiment has a different arrangement for placing and supporting the lifting assemblies 54 of FIGS. 12 and 13 . Rather, the lifting assemblies of FIGS. 12 and 13 are replaced with lifting assemblies or lifting eyes 193 , 194 , 195 , 196 as seen in FIGS. 41 , 44 , 46 - 47 , 65 and 67 as examples.
[0085] In the embodiment of FIGS. 24A-71 , there is no center column or central column 41 . Rather, a bracing arrangement is provided for each of the lifting eyes or lifting assemblies 193 , 194 , 195 , 196 by placing each lifting eye or lifting assembly 193 - 196 upon the top of an outer diagonal support 180 - 183 as shown in FIGS. 28 , 29 , 31 , 40 , 41 , 44 , 46 , 47 , 50 . As with the preferred embodiment, the cargo rack 170 provides upper horizontal members. However, for rack 170 the upper horizontal members include four upper interior horizontal supports 172 , 173 , 174 , 175 and four upper outer horizontal supports 188 , 189 , 190 , 191 .
[0086] In addition to the outer diagonal supports 180 , there are four inner diagonal supports 184 , 185 , 186 , 187 . In FIG. 41 , there can be seen a connection between a lifting eye 193 with an upper interior horizontal support 172 , an upper outer horizontal support 188 , and an outer diagonal support 180 . Each outer diagonal support 180 is inclined and is generally aligned with the lifting line of a crane, or with a sling or other lifting cable or device that is attached to the pin 197 of the lifting eye 193 . There is thus provide a recess 198 for receiving a loop end portion of a sling that is used to lift the cargo rack 170 .
[0087] In the embodiment shown, there would be four lifting eyes or lifting assemblies 193 - 196 , one for each of four slings. Each lifting eye, 193 - 196 , can be spaced in between a pair of corners. Such slings would be attached to a crane and to the cargo rack 170 such as the four such slings 80 shown in FIG. 11 of the preferred embodiment of FIGS. 1-23 . Each upper interior horizontal support 172 , 173 , 174 , 175 is welded or otherwise connected to another of said upper interior horizontal supports 172 , 173 , 174 , 175 at the center of the rack 170 frame 171 as shown. Each upper outer horizontal support 188 , 189 , 190 , 191 attaches to an intermediate column such as column 193 shown in FIGS. 28 , 29 , 34 , 40 and 41 . Each upper outer horizontal support 188 - 191 attaches to an intermediate column 33 , 34 , 35 , or 36 .
[0088] In FIG. 40 , each lower interior horizontal support 176 , 177 , 178 , 179 attaches to another of said lower interior horizontal supports 176 - 179 as shown in FIG. 40 . Such lower interior horizontal supports 176 - 179 also attach to an intermediate column such as the column 33 shown in FIG. 40 .
[0089] The following is a list of suitable parts and materials for the various elements of a preferred embodiment of the present invention.
[0000]
PARTS LIST
PART NO.
DESCRIPTION
10
cargo rack
11
frame
12
upper end portion
13
lower end portion
14
base
15
bottom
16
floor
17
floor segment/quadrant
18
floor segment/quadrant
19
floor segment/quadrant
20
floor segment/quadrant
21
gate/door
22
gate/door
23
gate/door
24
gate/door
25
hinge
26
hinge
27
hinge
28
hinge
29
corner column
30
corner column
31
corner column
32
corner column
33
intermediate column
34
intermediate column
35
intermediate column
36
intermediate column
37
upper interior horizontal support
38
upper interior horizontal support
39
upper interior horizontal support
40
upper interior horizontal support
41
central column
42
diagonal support
43
diagonal support
44
diagonal support
45
diagonal support
46
lower interior horizontal support
47
lower interior horizontal support
48
lower interior horizontal support
49
lower interior horizontal support
50
plate section
51
plate section
52
plate section
53
plate section
54
lifting assembly
55
lifting assembly
56
lifting assembly
57
lifting assembly
58
peripheral horizontal member
59
upper central fitting
60
lifting flock/body
61
side surface
62
side surface
63
front surface
64
rear surface
65
upper end portion
66
lower end portion
67
recess/slot
68
opening
69
pin
70
annular groove
71
plate
72
plate
73
opening
74
opening
75
bolt
76
opening
77
slot
78
cover plate
79
nut
80
sling/lift line
81
eyelet
82
lifting implement/hook/crown block
83
ring/shackle/lifting fitting
84
header/manifold
85
base interior
86
bottom panel
87
beam
88
beam
89
opening/bore
90
opening/bore
91
discharge/outlet fitting/coupling
92
valve
93
valve handle
94
flow line
95
flow line
96
flow line
97
flow line
98
swivel
99
riser
100
elbow fitting
101
elbow fitting
102
hose section
103
quick connect fitting
104
arrow
105
tank/module
106
tank discharge flow line
107
tank discharge valve
108
arrow
109
Tee fitting—lock
110
stacking fitting
111
gusset/stiffener plate
112
horizontal plate
113
vertical plate
114
vertical plate
115
module receptacle
116
lower plate
117
vertical plate
118
vertical plate
119
tank/module foot
120
opening/slot
121
drain channel
122
flow bore
123
floor opening
124
drain channel inlet opening
125
arrow
126
drain flow pipe
127
cap
128
arrow
129
outlet valve
130
vertical member
131
vertical member
132
vertical member
133
vertical member
134
horizontal member
135
horizontal member
136
upper plate
137
upper plate opening
138
rod
139
rod
140
vertical flanged member
141
vertical flanged member
142
sleeve
143
sleeve
144
upper rod guide
145
upper rod guide
146
lower rod guide
147
lower rod guide
148
rod opening
149
lower plate
150
horizontal flange
151
horizontal flange
152
lower plate opening
153
lever
154
lever
155
lever opening
156
lever opening
157
Tee fitting—unlock
158
vertical plate
159
vertical plate
160
arrow
161
arrow
162
arrow
163
Tee fitting—lock
170
cargo rack
171
frame
172
upper interior horizontal support
173
upper interior horizontal support
174
upper interior horizontal support
175
upper interior horizontal support
176
lower interior horizontal support
177
lower interior horizontal support
178
lower interior horizontal support
179
lower interior horizontal support
180
outer diagonal support
181
outer diagonal support
182
outer diagonal support
183
outer diagonal support
184
inner diagonal support
185
inner diagonal support
186
inner diagonal support
187
inner diagonal support
188
upper outer horizontal support
189
upper outer horizontal support
190
upper outer horizontal support
191
upper outer horizontal support
193
lifting eye, lifting assembly
194
lifting eye, lifting assembly
195
lifting eye, lifting assembly
196
lifting eye, lifting assembly
197
pin
198
recess
[0090] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.
[0091] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A cargo rack for transferring loads between a marine vessel and an offshore marine platform (for example, oil and gas well drilling or production platform) provides a frame having a front, a rear, and upper and lower end portions. The lower end of the frame has a perimeter beam base, a raised floor and a pair of open-ended parallel fork tine tubes or sockets that communicate with the perimeter beam at the front and rear of the frame, preferably being structurally connected (e.g., welded) thereto. Openings in the perimeter beam base align with the forklift tine tubes or sockets. The frame includes a plurality of fixed side walls extending upwardly from the perimeter beam that include at least left and right side walls. A plurality of gates are movably mounted on the frame including a gate at least at the front and at least at the rear of the frame, each gate being movable between open and closed positions, the gates enabling a forklift to place loads on the floor by accessing either the front of the frame or the rear of the frame. Each gate can be pivotally attached to a fixed side wall. The frame has vertically extending positioning beams or lugs that segment the raised floor into a plurality of load-holding positions. Each load holding position has a plurality of positioning beams or lugs that laterally hold a load module (e.g., palletized load) in position once a load is placed on the raised floor. | 1 |
RELATED APPLICATION
[0001] This application claims priority under 35 USC. §119(e) to U.S. Provisional Patent Application No. 61/511,178 filed on Jul. 25, 2011. The entire disclosure of this provisional application is hereby incorporated by reference.
BACKGROUND
[0002] Law enforcement personnel are part of every culture in our world and many of them carry handguns in the performance of their duties. In many organizations, each individual law enforcement officer is issued a firearm for which he/she is accountable both on and off duty. When the officer returns home after work, protocol usually requires that the gun be locked in a safe to prevent theft by criminals and/or contact by children.
SUMMARY
[0003] A handgun safe is provided which is especially suited for use in a home setting and/or for law-enforcement gun storage during off-duty hours. The safe can be opened only upon confirmation of biometric parameters of an authorized person.
DRAWINGS
[0004] FIGS. 1-2 show the handgun safe in a closed condition and in an open condition, respectively.
[0005] FIG. 3 shows the handgun safe with its door being invisible so as to reveal the locking mechanism.
[0006] FIG. 4 shows electronic components of the handgun safe.
DESCRIPTION
[0007] Referring now to the drawings, and initially to FIGS. 1 and 2 , a handgun safe 10 is shown which can be used to store a handgun 11 in a home setting. The safe 10 comprises a housing 20 defining a gun-storage chamber 21 sized to receive the handgun 11 . When the safe 10 is closed ( FIG. 1 ), the walls 22 - 26 of the housing 20 define a strong and secure envelope around the gun-storage chamber 21 . The housing walls 22 - 26 can be relatively thick and/or comprise steel bars disposed within concrete. In any event, the housing 20 is constructed so at to prevent access to the gun-storage chamber 21 by breaking through its walls 22 - 26 .
[0008] The housing 20 is preferably self-standing, that it is the housing 20 is not part of another piece of furniture or building structure. In this manner, the handgun safe 10 can be placed on a dresser, table, shelf or other convenient surface on a home setting. Additionally or alternatively, the housing 20 is compactly sized so as to not monopolize space in a bedroom or other domestic locale. The housing 20 can be, for example, less than twenty inches long, less than twenty inches wide, and less than ten inches tall.
[0009] The housing 20 can comprise a cabinet 30 and a door 40 . The door 40 is movable between a closed position ( FIG. 1 ) whereat access to the gun-storage chamber 21 is prevented and an opened position ( FIG. 2 ) whereat access to the gun-storage chamber 21 is allowed. Thus, to introduce the handgun 11 to the storage chamber 21 or remove it therefrom, the door 40 is moved to its opened position. The housing 21 can include a hinge 22 , or other means, for movably mounting the door 40 on the cabinet 30 .
[0010] The illustrated cabinet 30 comprises a front wall 32 , a rear wall 33 , side walls 34 , a top wall 35 , and a bottom wall 36 . The illustrated door 40 comprises a front face 42 , a rear face 43 , side edges 44 , a top edge 45 , and a bottom edge 46 . The cabinet's walls 33 - 36 form the corresponding walls 23 - 26 of the housing 20 , and the door 40 forms the front wall 22 of the housing 20 . The hinge 27 extends between the cabinet's top wall 35 and the door's top edge 45 whereby the door 40 pivots upward and downward when moving between the closed and opened positions.
[0011] The cabinet 30 includes a window 37 which communicates with the gun-storage chamber 21 . The door 40 includes an inset 47 which fits inside window 37 when the door 40 is in the closed position.
[0012] As is best seen by referring additionally to FIG. 3 , the handgun safe 10 comprises a locking mechanism 50 which is convertible between a locked condition and an unlocked condition. In the locked condition, the door 40 is locked in its closed position. In the unlocked condition, the door is unlocked for selective movement between its closed position and its opened position.
[0013] The illustrated locking mechanism 50 comprises two locking devices 51 contained within the inset 47 in the door 40 . In the illustrated embodiment, each locking device 51 includes two deadbolts 52 which shift between an extended stance and retracted stance to convert the locking mechanism between its locked condition and its unlocked condition. In the extended stance, the deadbolts 52 protrude laterally outward from the door inset 47 and into aligned cylindrical receipts 53 in the front wall 32 of the cabinet 30 .
[0014] The locking mechanism 50 and/or the locking devices 51 are electronically activated to move from the locked condition to the opened condition. The locking device 51 can comprise, for example, solenoid structures having plungers operably coupled to the deadbolts 52 . The deadbolts 52 can remain in the extended stance in the absence of electrical activation and shift to the retracted stance upon electrical activation. In this manner, the safe 10 will remain locked in the event of a power outage.
[0015] The handgun safe 10 comprises a biometric identifier 60 which allows only a pre-enrolled person to convert the locking mechanism 50 from its locked condition to its unlocked condition. The identifier 60 includes a biometric sensor 61 which, in the illustrated embodiment, resides on the top wall 25 of the housing 20 (i.e., also the top wall 35 of the cabinet 30 ) and is adapted to sense a person's fingerprint. A liftable lid 62 can cover the sensor 61 and camouflage it when the identifier 60 is not in use.
[0016] As is best seen by referring additionally to FIG. 4 , the handgun safe 10 comprises a microprocessor 70 which coordinates with the biometric identifier 60 to operate the locking mechanism 50 . Specifically, for example, the microprocessor 70 receives input from the biometric sensor 61 and its interpreter 63 verifying that an enrolled person wishes to open the handgun safe 10 . The microprocessor 70 then electrically activates the locking devices 51 so as to shift the deadbolts 52 from their extended stance to their retracted stance. The door 40 is then pivoted upwardly to allow access to the gun-storage chamber 21 .
[0017] Enrollment of a person as an authorized user of the handgun safe 10 can be accomplished by one or more designated enrollment managers. Such a manager can be appointed, for example, by the law enforcement organization issuing firearms to personnel. The microprocessor 70 can be pre-programmed with the relevant biometrics of the managers so as to allow them (and only them) the ability to enroll a person with the right to open the safe 10 .
[0018] When a specific handgun safe 10 has been assigned to a particular person, the manager inputs his/her biometrics into the sensor 61 , and initiates the enrollment progress via typing a code into the keypad 71 , and introduces the enrollee's biometrics via the sensor 61 . Thereafter, only this enrollee will be able to actuate opening of the handgun safe 10 .
[0019] The keypad 71 (or other programming equipment) can be integrally formed with the handgun safe 10 , such as in its housing 20 . However, as shown, the keyboard 71 can be part of a personal computer connected to the microprocessor 70 to perform the enrollment progress.
[0020] The handgun safe 10 can include an activity monitor 80 which works in conjunction with the microprocessor 70 to monitor activity. Upon insertion of the handgun 11 into the storage chamber 21 , a reader 81 can recognize this particular gun per a unique tag thereon and convey this information to the microprocessor 70 . The reader 81 and the gun tag can be, for example, an RFID reader and an RFID tag.
[0021] The microprocessor 70 can confirm (e.g., with proximity switches) that the door 40 has been moved to its closed position and the locking mechanism has been converted to its locked condition. A data package is created containing the identity of the person opening the safe 10 , the recognition of the gun 11 , the closing of the safe 10 , and time stamps for these events. This data package can be conveyed via wireless module 82 to a remote supervisory station. Some or all of this data can be displayed on a screen 83 situated, for example, on the door 40 (i.e., the front wall 22 of the housing 20 ).
[0022] The handgun safe 10 can comprise a music system 90 including, for example, a docking station 91 for a personal music storage device, speakers 92 , and control dials 93 . In the illustrated embodiment, the docking station 91 is built into the top wall 35 of the cabinet 30 (i.e., top wall 25 of the housing 20 ), the speakers 92 are built into the side walls 34 of the cabinet 30 (i.e., the side walls 24 of the housing 20 ), and control dials 93 are built into the door 40 (i.e., the front wall 22 of the housing 20 ). The door 40 can further include speaker-compatible compartments 94 aligned with the speakers 92 when in its closed position.
[0023] The incorporation of a music system 90 into the safe 10 not only doubles its utility, but also disguises the seriousness of its primary purpose. Depending upon other aesthetics, the safe 10 could be overlooked as a gun-guarding receptacle by unfamiliar eyes.
[0024] The locking mechanism 50 , the biometric identifier 60 , the microprocessor 70 , the activity monitor 80 , and the music system 90 can be supplied with electrical power via power supply 100 . The power supply 100 can include, as illustrated, a plug 101 for a standard 120 vac outlet found in most homes. Battery backup 102 can also be provided to accommodate power outages.
[0025] In a residential setting, for example, where a citizen wants to store his or her handgun, the safe 10 can be shipped with the door 40 ajar. Once power is applied (e.g., via a battery or wall outlet), an administrative button can be pushed to begin authorization enrollment. This button can be located, for example, inside the cabinet 30 and/or within the storage chamber 21 . A signal can then be sent that swiping of fingerprint features (e.g., thumbprint features) can begin on the biometric identifier 60 . A plurality of “good swipes” can be required for enrollment, with signals verifying swipe sufficiency. The signals can comprise, for example, lights (e.g., leds) which shine green for good, red for bad, yellow for issues, etc.
[0026] Once the person's fingerprint features are accepted, he or she is authorized to open the safe 10 . If the authorized person swipes the biometric identifier a signal can be provided and the locking mechanism 50 converted to its open condition by the microprocessor. If a nonauthorized person swipes the biometric identifier, a “no access” signal can be provided and the locking mechanism can remain in its closed condition.
[0027] If the safe 10 is registered with the manufacturer or other monitoring entity, an alert (e.g., email or text) will be sent to the customer if and when a new authorized person is added.
[0028] The safe 10 can include additional and/or alternative alerts, to indicate tampering, no power, heartbeats etc. Courtesy reminders, regarding safe-opening times, can be provided, which may have special applicability when the safe 10 is used to store pharmaceutical products which should be administered during certain time frames.
[0029] One may now appreciate that a handgun safe 10 is provided with is especially suited for use in a home setting and/or can effectively monitored at a remote supervisory site. Although the safe 10 , the housing 20 , the cabinet 30 , the door 40 , the locking mechanism 50 , the biometric identifier 60 , the microprocessor 70 , the activity monitor 80 , the music system 90 , and/or the power supply 100 have been shown and described with respect to a certain embodiment or embodiments, equivalent alterations and modifications will occur to others skilled in the art upon review of this specification and the annexed drawings. For example, the safe 10 can be used to store sensitive items other than guns, such as pharmaceutical products.
REFERENCE NUMBERS
[0000]
10 =gun safe
20 =housing
21 =gun-storage chamber
22 =housing front wall
23 =housing rear wall
24 =housing side walls
25 =housing top wall
26 =housing bottom wall
27 =cabinet-door hinge
30 =cabinet
32 =cabinet front wall
33 =cabinet rear wall
34 =cabinet side walls
35 =cabinet top wall
36 =cabinet bottom wall
37 =window
40 =door
42 =door front wall
43 =door rear wall
44 =door side edges
45 =door top edge
46 =door bottom edge
47 =window inset
50 =locking mechanism
51 =locking units
52 =deadbolts
53 =cylindrical receipts
60 =biometric identifier
61 =sensor
62 =lid
63 =interpreter
70 =microprocessor controller
71 =keypad
80 =monitoring system
81 =reader
82 =wireless module
90 =music system
91 =docking station
92 =speakers
93 =dials
94 =speaker compartments
100 =power supply
101 =120 vac
102 =battery backup | A safe ( 10 ) comprising a housing ( 20 ) defining a storage chamber ( 21 ), a door ( 40 ) moveable between closed and opened positions, a locking mechanism ( 50 ) convertible between locked and unlocked conditions, and biometric identifier ( 60 ) which senses biometric features to identify a person attempting to access the storage chamber ( 21 ). A microprocessor ( 70 ) causes conversion of the locking mechanism ( 50 ) from its locked condition to its unlocked condition upon identification by the biometric identifier ( 60 ) of authorized use. The safe ( 10 ) can be used, for example, to store a handgun. | 4 |
BACKGROUND
[0001] This disclosure relates generally to estimating a road grade and, more particularly, to estimating road grade below a trailered vehicle.
[0002] Towing vehicles tow trailered vehicles. A truck is an example towing vehicle. A boat trailer is an example trailered vehicle. Both are example vehicles.
[0003] Extreme road grades may cause a trailered vehicle to exert considerable pulling force on the towing vehicle. If the towing vehicle does not account for this pulling force, the towing vehicle braking force may be insufficient.
[0004] The road grade beneath a vehicle can be used to determine a road gradient load torque. Measuring or estimating road grade beneath a vehicle is useful for at least this reason.
[0005] Although a towing vehicle and a trailered vehicle are in close proximity during towing, the road grade beneath the towing vehicle may differ considerably from the road grade beneath the trailered vehicle. Although sensors mounted to towing vehicles have been used to suitably estimate road grade beneath the towing vehicles, monitoring the road grade beneath the trailered vehicle is difficult. Towing vehicles are rarely equipped with sensors capable of monitoring road grade.
SUMMARY
[0006] A vehicle control method according to an exemplary aspect of the present disclosure includes, among other things, controlling a towing vehicle based upon a trailered vehicle road grade.
[0007] In another example of the foregoing method, the trailered vehicle road grade is based upon a towing vehicle road grade of the towing vehicle.
[0008] In another example of any of the foregoing methods, the trailered vehicle road grade at a position is based upon the towing vehicle road grade at the position.
[0009] In another example of any of the foregoing methods, the method includes recording the towing vehicle road grade when the towing vehicle tows the trailered vehicle forward, and shifting the recording of the towing vehicle road grade to calculate the trailered vehicle road grade, wherein the shifting comprises a spatial domain shift of the towing vehicle road grade.
[0010] In another example of any of the foregoing methods, the method includes initiating a vehicle control adjustment in response to the trailered vehicle road grade.
[0011] In another example of any of the foregoing methods, the vehicle control adjustment comprises increasing braking force applied to the towing vehicle in response to the trailered vehicle road grade.
[0012] In another example of any of the foregoing methods, the trailered vehicle road grade is an estimated trailered vehicle road grade.
[0013] A system for controlling a towing vehicle according to an exemplary aspect of the present disclosure includes, among other things, a sensor to monitor a towing vehicle road grade of the towing vehicle, and a controller configured to control the towing vehicle based upon a trailered vehicle road grade.
[0014] In another example of the foregoing system, the trailered vehicle road grade is based upon the towing vehicle road grade.
[0015] In another example of any of the foregoing systems, the towing vehicle is configured to tow the trailered vehicle.
[0016] In another example of any of the foregoing systems, the sensor assembly is mounted to the towing vehicle.
[0017] In another example of any of the foregoing systems, the controller is mounted to the towing vehicle.
[0018] In another example of any of the foregoing systems, the trailered vehicle road grade at a position is based upon the towing vehicle road grade at the position.
[0019] A system for controlling a towing vehicle according to another exemplary aspect of the present disclosure includes, among other things, a road grade assembly providing a towing vehicle road grade, and a trailered road grade based upon the towing vehicle road grade, and a controller configured to adjust operation of the towing vehicle based upon the trailered vehicle road grade.
[0020] In another example of the foregoing system, the controller adjusts vehicle braking based upon the trailered vehicle road grade.
[0021] In another example of any of the foregoing systems, the controller adjusts vehicle cruise control based upon the trailered vehicle road grade.
[0022] In another example of any of the foregoing systems, the controller adjusts a transmission shift schedule based upon the trailered vehicle road grade.
[0023] In another example of any of the foregoing systems, the trailered vehicle road grade at a position is based upon the towing vehicle road grade at the position.
[0024] A system for controlling a towing vehicle according to yet another exemplary aspect of the present disclosure includes, among other things, a controller configured to adjust operation of the towing vehicle based upon a trailered vehicle road grade.
[0025] In another example of the foregoing system, the controller adjusts vehicle braking based upon the trailered vehicle road grade.
[0026] In another example of any of the foregoing systems, the controller adjusts vehicle cruise control based upon the trailered vehicle road grade.
[0027] In another example of any of the foregoing systems, the controller adjusts a transmission shift schedule based upon the trailered vehicle road grade.
[0028] In another example of any of the foregoing systems, the system includes a road grade sensor assembly to sense a towing vehicle road grade, and to provide a trailered road grade.
[0029] In another example of any of the foregoing systems, the trailered vehicle road grade at a position is based upon the towing vehicle road grade at the position.
DESCRIPTION OF THE FIGURES
[0030] The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The figures that accompany the detailed description can be briefly described as follows:
[0031] FIG. 1 illustrates an example towing vehicle towing a trailered vehicle.
[0032] FIG. 2 illustrates a length between the towing vehicle of FIG. 1 and the towing vehicle and trailered vehicle of FIG. 1 .
[0033] FIG. 3 illustrates a map of a towing vehicle road grade and trailered vehicle road grade verses distance traveled.
[0034] FIG. 4 shows a flowchart of an example method for determining the road grade of the trailered vehicle of FIG. 1 .
[0035] FIG. 5 illustrates another length between the towing vehicle of FIG. 1 and another example trailered vehicle.
DETAILED DESCRIPTION
[0036] Referring to the example of FIG. 1 , a towing vehicle 10 tows a trailered vehicle 14 . The towing vehicle 10 is a truck in this example, and the trailered vehicle 14 is a trailered boat. Both are example vehicles. A mechanical arm 18 couples the towing vehicle 10 to the trailered vehicle 14 .
[0037] For a given vehicle towed, its associated road grade is, generally, a grade (or slope) of an area beneath the vehicle. Road grade can be expresses as a percentage of variation from a horizontal (zero) grade H g .
[0038] A towing vehicle road grade RG TOWING is a grade of an area of the road beneath the towing vehicle 10 . A trailered vehicle road grade RG TRAILER is a grade of a road beneath the trailered vehicle 14 . In this example, the trailered vehicle road grade RG TRAILER is greater than a grade of the towing vehicle road grade RG TOWING .
[0039] Although described as road grade, a person having skill in this art and the benefit of this disclosure would understand that a traditional road is not required for there to be a road grade. Road grade refers generally to the area underneath a vehicle whether that area is a road or that area is an off-road.
[0040] The towing vehicle 10 includes a sensor assembly 20 that monitors the towing vehicle road grade RG TOWING . The assembly may include accelerometers, wheel speed sensors, etc. A person having skill in this art and the benefit of this disclosure would understand how to monitor, or estimate, the towing vehicle road grade RG TOWING using the sensor assembly 20 .
[0041] The towing vehicle 10 further includes a controller assembly 30 coupled to the sensor assembly 20 . The controller assembly 30 is a specialized controller programed to estimate the trailered vehicle road grade RG TRAILER based on the towing vehicle road grade RG TOWING . The controller assembly 30 and sensor assembly 20 together provide a trailered vehicle road grade assembly or a system for controlling the trailered vehicle 14 .
[0042] Notably, the example trailered vehicle 14 includes no sensor assembly or controller assembly to monitor the trailered vehicle road grade RG TRAILER . In other examples, the trailered vehicle 14 may include the sensor assembly 20 , the controller assembly 30 , or both.
[0043] In this example, the towing vehicle 10 has towed the trailered vehicle for a drive distance D from a start location S to the location shown in FIG. 1 . The towing vehicle 10 , and thus the sensor assembly 20 , has passed over a position P 1 .
[0044] As the towing vehicle 10 has passed over the position P 1 , the towing vehicle road grade RG TOWING at the position P 1 was previously calculated and measured. The controller assembly 30 includes a memory buffer that records or stores the measurement of the towing vehicle road grade RG TOWING .
[0045] After the trailered vehicle 14 is positioned over the position P 1 . The controller assembly 30 applies the stored measurement of the towing vehicle road grade RG TOWING (when the towing vehicle 10 was at the position P 1 ) as the trailered vehicle road grade RG TRAILER . The towing vehicle 10 is thus used as a road grade sensor for the trailered vehicle 14 .
[0046] Referring now to FIG. 2 with continuing reference to FIG. 1 , the controller assembly 30 can use a length L between the sensor assembly 20 of the towing vehicle 10 and the midpoint 40 of the trailered vehicle 14 when calculating the trailered vehicle road grade RG TRAILER . In some examples, as the towing vehicle 10 tows the trailered vehicle 14 for the drive distance D, the controller assembly 30 records the towing vehicle road grade RG TOWING for various positions along the drive distance D. Each of the position across the drive distance D has a corresponding towing vehicle road grade RG TOWING .
[0047] To calculate the trailered vehicle road grade RG TRAILER , the controller assembly 30 effectively shifts towing vehicle road grades RG TOWING the length L, which corresponds to the distance between the sensor assembly 20 and the mid-point 40 of the trailered vehicle 14 . The shift is within a spatial domain having the length L.
[0048] The road grade for the trailered vehicle 14 is estimated based using length L from the sensor assembly 20 to the midpoint 40 . The sensor assembly 20 is at the center of gravity g of the towing vehicle 10 , and the midpoint 40 is at the center of gravity g of the trailered vehicle 14 .
[0049] Other areas of the towing vehicle 10 , the trailered vehicle 14 , or both could be used. Such adjustments are possible by changing the length L.
[0050] After calculating the trailered vehicle road grade RG TRAILER , the controller assembly 30 can provide the trailered vehicle road grade RG TRAILER to control operations for the towing vehicle 10 . The towing vehicle 10 may make vehicle control adjustments in response to the trailered vehicle road grade RG TRAILER . In one example, the vehicle control adjustments include applying more braking force to the towing vehicle 10 to prevent the trailered vehicle 14 from destabilizing or pulling the towing vehicle 14 . In another example, the vehicle control adjustments include adjusting a cruise control setting of the towing vehicle 10 , or a transmission shift schedule of the towing vehicle 10 . The example controller assembly 30 of the system for controlling the trailered vehicle 14 thus adjusts operation of the towing vehicle based on the trailered vehicle road grade RG TRAILER .
[0051] For example, information about the trailer road grade RG TRAILER can be used by a cruise controller of the towing vehicle 10 to adjust the powertrain torque delivery in a feedforward manner. Information about the trailer road grade RG TRAILER can be used by a transmission controller of the towing vehicle 10 to adjust its gear scheduling strategy such that gear shifting will be smoother and optimized when the trailered vehicle 14 is adding additional load to the towing vehicle 10 .
[0052] As can be appreciated, the load on the towing vehicle 10 resulting from road grade can vary greatly when the trailered vehicle 14 is attached to, or detached from, the towing vehicle 10 .
[0053] FIG. 3 shows a map or visual representation of the shift between the towing vehicle road grades RG TOWING , which are represented as line 50 , and the trailered vehicle road grades RG TRAILER , which are represented as line 54 .
[0054] In one example method of estimating the towing vehicle road grades RG TOWING , an evaluation range is defined by l e , which is a distance parameter covering the largest allowable distance of the trailered vehicle 14 behind the towing vehicle 10 .
[0055] Next, in the method, an evaluation step distance l e is defined. The evaluation step distance l e represents the driving distance elapsed between consecutive recordings of the towing vehicle road grade RG TOWING by the sensor assembly 20 as the towing vehicle 10 moves together with the trailered vehicle 14 . The evaluation distance l e can be one meter, for example. In such an example, the towing vehicle road grade RG TOWING is recorded every meter as the towing vehicle 10 moves together with the trailered vehicle 14 .
[0056] The method populates a vector of road gradient estimation record with the towing vehicle road grade RG TOWING recordings. This vector is defined by V rg and has dimensions determined by L e /l e . A buffer length V b is provided by a rounded integer number, such as V b =round(L e /l e ).
[0057] The buffer provide memory for a sequence of values. The buffer length V b is determined by the number of values needed. The more values needed, the longer buffer length V b .
[0058] The method saves the measurements of the towing vehicle road grade RG TOWING as V rg [k]. The trailered vehicle road grade RG TRAILER are then k*l e behind the evaluation point of the towing vehicle 10 .
[0059] V rg [k] can be initialized with zeros, or with records from a previous driving cycle. After initializing V rg [k], new towing vehicle road grades RG TRAILER are collected, and the vector of recorded road grades V rg [k] will shift backwards to pass a k-th record to a k+1 record position. The estimations have a length of L e after the record of V rg [1]. The record at k=V b is then dropped and replaced by the record at k=V b −1.
[0060] The method essentially provides a signal buffer. The method may be executed on software within the controller assembly 30 of the towing vehicle 10 .
[0061] The proposed method is often most effective when the towing vehicle 10 is pulling or leading the trailered vehicle 14 . When reversing, there may not be a towing vehicle road grade measurement available. In that case, the records of road grade are shifted forward by removing signal recorded at k=0. Meanwhile, each buffer cell at k will be replaced by the value from its subsequent record at k+1. The record at k=V b will then be fed by zero since no new information will be available from the trailer side.
[0062] Referring now to FIG. 4 , an example of the above method is summarized in a flowchart 100 . Generally, the flowchart 100 shows that by integrating the speed signal, an algorithm knows how far the towing vehicle 10 towing the trailered vehicle 14 have moved since a previous update. Then, when a distance traveled forward by the vehicles is longer than a step distance, an update process will start if new data is available from the towing vehicle 10 .
[0063] More specifically, in the flowchart 100 , V spd stands for vehicle speed, which is typically expressed in unit of meters per second. In the flowchart 100 , dt stands for control implementation cycle time, and NA represents not available, such as when an implausible value is provided. Rather than NA, the method may, in another example, use a quality factor associated with V rg [1] to calculate whether the road information at a distance after the towing vehicle 10 can be used for control or not. Further, in FIG. 4 , l_E is the step distance, for example, it can be 3 meters. v_b is the number of memory unit needed to save the road grade information at l_E step size up to L_E total length.
[0064] After V rg is available, the trailered vehicle road grade RG TRAILER can be evaluated. Due to variety of sizes and types of trailered vehicles 14 , the distance of the road slope evaluation point of the trailer behind the evaluation point of the truck is not fixed. In the example of FIG. 5 , for example, a trailered vehicle 14 ′ has a single axle 60 , and the length L′ is a length from the sensor assembly 20 to the axle 60 .
[0065] The length L or L′ typically varies from 10 to 20 meters for commonly used utility trailers and RVs. The evaluation of the trailered vehicle road grade RG TRAILER is done across a range rather than at a point to accommodate this variation.
[0066] In some examples, two distance parameters, L MIN and L MAX are specified for the control algorithm and 0≦L MIN ≦L MAX ≦L_E executed to calculate the trailered vehicle road grade RG TRAILER . For example, L MIN =10 meters L MAX =15 meters could be used. An evaluation vector Vect_RG TRAILER is constructed out of V rg by V rg [k], L MIN ≦k*L_E≦L MAX . The final road grade under the trailer for control applications is evaluated with the vector Vect_RG TRAILER .
[0067] In some examples, the method may use the largest absolute value from Vect_RG TRAILER .
[0068] In some examples, the method can use a mean value of Vect_RG TRAILER to provide an estimate of the average level of the road grade under the trailer.
[0069] In some examples, the method may use a standard deviation value of V rg . When the standard deviation is above a threshold, a maximal magnitude of is used. Otherwise, the mean value of is used for the subsequent control algorithm processing.
[0070] A quality of the final evaluation of the trailered vehicle road grade RG TRAILER depends, in part, on the number of NAs in the vector V rg [k]. A ratio between the numbers of the valid estimation to NAs can be used to indicate the quality of evaluation.
[0071] Methods having flows different than the method of the flowchart 100 may be utilized to calculate the trailered vehicle road grade RG TRAILER in view of the towing vehicle road grade RG TOWING .
[0072] Features of the disclosed examples include a method and estimator capable of evaluating road grade under a trailered vehicle without the use of complex sensors on the trailered vehicle or an electric coupling between the trailered vehicle and the towing vehicle.
[0073] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. Thus, the scope of legal protection given to this disclosure can only be determined by studying the following claims. | An example vehicle control method includes, among other things, controlling a towing vehicle based upon a trailered vehicle road grade. | 1 |
The invention relates to a tufting apparatus and process that forms the face of the carpet on the top side of the primary backing material or substrate and the method of operating the tufting apparatus.
In a tufting machine, the face of the carpet is generally formed by loopers operating beneath the substrate. The top side of the substrate shows only the backstitch. In these tufting machines, one or more rows of yarn carrying needles are reciprocally driven through the substrate being fed through the machine across a bed plate to form loops that are seized by loopers oscillating below the substrate and bed plate in timed relationship with the needles. Numerous modifications have been made to such tufting machines in order to create a variety of fabric textures and designs. For instance, to change the depth of the pile height produced by a tufting machine various methods have been devised to change the length of the stroke of the needles, and the elevation of the bed plate relative to the loopers as in U.S. Pat. Nos. 2,977,905 and 3,332,379. It is also possible to add a knife block to operate in cooperation with the loopers to produce cut pile rather than looped pile fabric as in U.S. Pat. Nos. 3,277,852 and 4,445,446 or even a combination of cut pile and loop pile as in U.S. Pat. Nos. 3,019,748 or 3,084,645. In order to produce patterned fabric various techniques have been devised to laterally move or "shog" the needle bar or substrate as in U.S. Pat. Nos. 3,393,654 and 4,173,192. In addition, a variety of yarn feeding devices have been developed to allow the creation of even more complicated patterns by back-robbing selected yarns so that the resulting loops are very low to the substrate and are "buried" by other higher adjacent loops, as in U.S. Pat. Nos. 2,862,465 and 3,103,187.
There is constant development of modified tufting equipment in an attempt to produce novel carpet designs. It is also desirable that carpet designs make efficient use of yarn so that a relatively high proportion of the yarn used is on the face of the carpet. Although it is necessary that some yarn appear on the back side of the substrate so that a strong tuft bond can be created by applying a latex backing or other adhesive to encapsulate the carpet fibers on the back side, the carpet industry has resisted placing additional yarn on the back side even if the resulting pattern is desirable.
The tufting industry is progressively evolving through innovation directed toward duplicating, or at least simulating, products which previously were only produced by weaving on a loom or on knitting machines. The evolution of such tufted products, combined with the substantially higher production rates of the tufting process relative to weaving has resulted in more universal availability of tufted products that resemble wovens. The present invention, denominated a "variable gauge tufting machine," provides the ability to produce novel variable gauge fabrics with an appearance that could only heretofore be produced by looms or knitting machines, as well as fabrics that have not heretofore been produced. Furthermore, the variable gauge tufting machine can produce these fabrics while leaving a relatively minimal amount of yarn on the back of the carpet.
Substantial advantages are achieved in fabrics manufactured with frequent shifting of the needle bar or bars. In such fabrics, the variable gauge tufting machine can achieve the same coverage of substrate with lower stitch rates than conventional tufting machines and less adhesive is generally required to encapsulate the carpet fibers on the back side of the substrate. An additional advantage is that during the manufacturing process, the face of the fabric is visible to the tufting machine operator so that defects are more quickly detected allowing correction of any problems with less wasted product and production time. Furthermore, the resulting fabrics are less resistant to sliding traffic, have increased abrasion resistance, and have a greater tendency to lie flat than ordinary tufted fabrics.
The fabrics manufactured according to the present invention, which are claimed in our copending application entitled Variable Gauge Fabrics and Method of Manufacture, have a wide range of applications, from carpet for floor covering and automotive uses, to wall coverings, upholstery and filters.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a method and apparatus for forming tufted fabrics in which the face of the fabric is in the form of transverse or diagonally transverse loop stitches or straight stitches and the backstitching consists of loop or cut pile tufts.
It is also an object of this invention to provide an apparatus to produce novel tufted fabrics which by the use of transverse or diagonally transverse loop stitches or straight stitches have the appearance of fabrics that could only heretofore be produced on looms or knitting machines, and other fabrics which have never heretofore been produced.
A tufting machine made in accordance with this invention has an additional "loop forming plate" mounted above the substrate with loop forming fingers extending rearward in the direction of the fabric feed. Transverse or diagonally transverse loop stitches are formed on the top surface of the substrate over the loop forming fingers by laterally shifting the needle bar relative to the substrate, after the needles' penetration of and retraction from the substrate. Fabrics with simple patterns involving only varying the gauge or lateral length of the loop stitches may be created by a tufting machine with a single needle bar, while more complex patterns may be created by a tufting machine with multiple needle bars.
A tufting machine incorporating the present invention with independently shiftable dual needle bars makes it possible to produce patterns in tufted fabric which have the appearance of patterns only heretofore produced on looms or knitting machines.
It is also possible to overtuft existing carpets and other fabrics utilizing the present invention to create patterns or an embroidered appearance.
It is a further object of the invention to allow the manufacture of more easily moldable carpet to be mounted on contoured surfaces such as automobile floorboards.
It is yet another object of the invention to allow the manufacture of fabrics which have the appearance of course fabrics on a fine gauge machine, through the use of relatively long laterally shifted stitches. By increasing the stitch rate, the appearance created by small yarns can be made to simulate the usual visual appearance of larger yarns.
It is another object of the invention to allow the manufacture of fabrics with unique textures by varying yarn densities across the face of the fabric by stitch rate and by the length of the laterally shifted stitches.
Although the preferred shift drive actuator for shifting the needle bar or bars is an electrohydraulic needle bar positioning apparatus, such as that described in U.S. Pat. No. 4,173,192, it is possible to shift a needle bar or bars with conventional mechanical shift actuators such as those incorporating pattern cams.
Other objectives and advantages of the invention will be best understood when reading the following detailed description with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view of a multiple needle bar tufting machine according to the present invention.
FIG. 2 is a fragmentary top plan view of the tufting machine of FIG. 1.
FIG. 3 is a sectional side view of a single needle bar tufting machine according to the present invention.
FIG. 4 is a side plan view of the crank adjustment for the loop forming plate shown in isolation.
FIG. 5 is a fragmentary side view of a single needle bar tufting machine according to the present invention showing the formation of a single column of diagonally transverse loop stitches on the top of the substrate.
FIG. 6 is a fragmentary top plan view of a single needle bar tufting machine according to the present invention, forming columns of diagonally transverse loop stitches.
FIG. 7A is a top plan view of a fabric formed according to the invention.
FIG. 7B is a sectional end view of the fabric pictured in FIG. 7A.
FIG. 7C is a bottom plan view of the fabric of 7A.
FIG. 8A is a top plan view of another fabric formed according to the invention.
FIG. 8B is a sectional end view of the fabric of 8A.
FIG. 8C is a bottom plan view of the fabric of 8A.
FIG. 9A is a top plan view of yet another fabric formed according to the invention.
FIG. 9B is a section end view of the fabric of 9A.
FIG. 9C is a bottom plan view of the fabric of 9A.
FIG. 10A is a top plan diagrammatic view of a series of loop stitches and straight stitches in a fabric formed by a single needle according to the invention.
FIG. 10B is a top plan diagrammatic view of the fabric of 10A formed by a plurality of needles in which the yarn has been backrobbed from selected stitches and the resulting untufted yarn loops sheared from the fabric.
FIG. 11 is a diagrammatic illustration of the fabric feed mechanism of the present invention.
FIG. 12A is a sectional end view of a fabric formed according to the present invention.
FIG. 12B shows the fabric of FIG. 12A sandwiched between two backing fabrics.
FIGS. 12C and 12D illustrate the fabrics formed when the sandwiched fabric of FIG. 12B is cut apart at its midpoint and the substrate is removed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 discloses a loop pile tufting machine 10 including a plurality of elongated transversely spaced needle bar carriers 11 supporting a front needle bar 12 and a rear needle bar 13. The front needle bar 12 supports a row of transversely spaced front needles 14, while the rear needle bar 13 supports a row of transversely spaced rear needles 15. Each needle bar carrier 11 is connected to a push rod 16 adapted to be vertically reciprocated by a conventional needle drive mechanism, not shown.
Front yarns 18 are supplied to the corresponding front needles 14 through corresponding apertures 19 in the front yarn guide plate 20 from a source of yarn supply, not shown, such as yarn feed rolls, creels, or other known yarn supply means. Preferably, the front yarns 18 pass through a yarn feed pattern control mechanism 21, adapted to feed the appropriate length of individual front yarns 18 to corresponding front needles 14 in accordance with a predetermined pattern. Any one of several pattern control mechanisms may be incorporated in the mechanism 21, such as those disclosed in U.S. Pat. Nos. 2,782,905 and 2,935,037.
In the same manner, rear yarns 22 are supplied to the corresponding rear needles 15 through corresponding apertures 23 in the rear yarn guideplate 24 from another source of supply for the yarns, not shown. In a preferred form of the invention, the rear yarns 22 are fed through a separate yarn feed pattern control mechanism 25 which may be independent of the front yarn feed pattern control mechanism 21 in order to permit the appropriate length of individual rear yarns 22 to be fed to corresponding rear needles 15, depending upon the predetermined pattern incorporated in the rear pattern control mechanism 25.
The front needle bar 12 and the rear needle bar 13 are shown slidably mounted in cooperation with front sliding rod 70 and rear sliding rod 71 which are mounted in linear ball bearing assemblies 72 to transversely or laterally shift the corresponding front needle bar 12 and rear needle bar 13. Each needle bar 12 and 13 may be transversely or laterally shifted independently of each other by appropriate pattern control means in a well known manner, such as the pattern controlled needle bar positioner mechanism 36 and corresponding push rods 37 and 38 (all shown in FIG. 2) connected to the respective front sliding rod 70 and rear sliding rod 71.
Again, referring to FIG. 1, supported upon a needle plate 32 and fixed to the bed frame 33 are a plurality of straight rearward projecting, transversely spaced, needle plate fingers 34 which project rearward between the vertical needle paths of the reciprocable front and rear needles 14 and 15. Supported for longitudinal rearward movement by conventional fabric feed mechanism or substrate drive (not shown) over the bottom needle plate 32 is the substrate or base fabric 35.
The needle drive mechanism, not shown, is designed to actuate push rods 16 to vertically reciprocate the pair of needle bars 12 and 13 to cause the front and rear needles 14 and 15 to simultaneously penetrate the substrate 35 far enough to carry the respective yarns 18 and 22 through the substrate 35 to form loops therein. After the loops are formed, the needles 14 and 15 are vertically withdrawn to their elevated retracted position disclosed in FIG. 1.
A looper apparatus 40 made in accordance with any of several such mechanisms, such as those disclosed in U.S. Pat. Nos. 4,800,828 and 3,973,505, includes a plurality of transversely spaced front loop pile hooks 41 and a plurality of transversely spaced rear loop pile hooks 42, there being at least one front loop pile hook 41 for each front needle 14 and at least one rear loop pile hook 42 for each rear needle 15. The front loop pile hooks 41 are so arranged that a bill 47 of a front hook 41 will cross and engage each front needle 14 when the front needle 14 is in its lower most position and in a well known manner to seize the yarn 18 and form a bottom pile loop 60 (as shown in FIG. 5) therein. The bills 47 of the front hooks 41 point rearward in the direction of fabric feed as indicated by the arrow 50
In a similar manner, the rear hooks 42 are so arranged that a bill 48 of a rear hook 42 will cross and engage each rear needle 15 when the rear needle 15 is in its lower most position and in a well known manner to seize the yarn 22 and form a bottom pile loop therein. The bills 48 of the rear loop pile hooks 42 point rearward in the same direction as the bills 47 of the front hooks 41 and the fabric feed 50.
The spacing or gauge of the hooks typically corresponds to the gauge of the needles. However, it is possible for the gauge of the hooks to be a multiple of the needle gauge in which case not every needle would be threaded with yarn so that there would still be a hook to cross and engage each threaded needle. It is also possible for the hook gauge to be a fraction of the needle gauge, or stated differently for the needle gauge to be a multiple of the hook gauge. In this case there are more hooks than needles.
In conventional tufting machine operation, the yarn feed pattern control mechanisms 21 and 25 would be programmed to back-rob certain front yarns 18 and rear yarns 22 in order to produce a desired high-low pile loop pattern. The yarns 18 and 22 can be selected from different colors or varying size or physical characteristics for the respective front and rear needles 14 and 15, or in some cases different yarns may be selected for various of the front needles 14 or for various of the rear needles 15. When it is desired to make even more complex patterns by shifting the needle bars 12 and 13, the pattern controlled needle bar positioning mechanism 36 is actuated in a well known manner. The machine 10 is then operated to produce the desired loop pile patterns in the substrate 35 as the substrate 35 moves in the direction of the arrow 50 rearwardly through the machine 10. In conventional operation, the patterns formed on the substrate 35 appear on the bottom surface 45 which faces the looper apparatus 40, while the upper surface 44 of the substrate 35 contains only the back stitching necessary to permit the needles 14 and 15 to move from one pile loop location to another.
A feature of the present invention is the addition of a loop forming plate 52 located forward of the needles 14 and 15 and above the substrate 35. Said loop forming plate 52 can be supported as illustrated by a member 55, descending from the head 26 of the tufting machine. On some tufting machines, the loop forming plate 52 can be inserted in place of an adjustable presser foot which is utilized to hold the substrate 35 proximate to the needle plate 32 when the needles are being vertically withdrawn to their elevated retracted position. Supported from the loop forming plate 52 are a plurality of straight rearward projecting, transversely spaced loop forming fingers 51 which project rearward between the vertical needle paths of the reciprocable rear and front needles 14 and 15. In most cases the spacing or gauge of the loop forming fingers 51 will correspond to the gauge of the hooks.
In operation, the front needles 14 and rear needles 15 are pushed through the substrate 35 to form pile loops on the bottom surface 45 in the conventional manner. Preferably these loops are made very low so that relatively little front yarn 18 or rear yarn 22 is on the bottom surface 45. When the front needles 14 and rear needles 15 are raised up through the substrate 35 and above the loop forming fingers 51 of the loop forming plate 52, the pattern controlled needle bar positioner 36 shown in FIG. 2 may be programmed to laterally displace the front needle bar 12 and corresponding front needles 14, or the rear needle bar 13 and corresponding rear needles 15, or both, from their previous positions. In typical carpet applications such lateral displacement is generally between one-tenth inch and one inch and is in units of distance equal to the spacing between the loop forming fingers 51 of the loop forming plate 52.
The yarn feed pattern control mechanisms 21 and 25 preferably provide the appropriate length of yarn for the length of lateral displacement of the needles. Then the needle drive mechanism again acts to force the push rods 16 downward, causing the front needles 14 and rear needles 15 to again penetrate the substrate 35. Pile loops are again formed on the bottom surface 45 in the conventional manner. As a result of the repetition of this action, the top surface 44 of the substrate 35 is covered with loop stitches that are transverse to the direction of the fabric feed 50. The direction of the fabric feed 50 imparts a slight diagonal to the stitches.
FIG. 5 shows a single needle 61 threaded with yarn 63 forming a column of diagonally transverse loop stitches 62 over a loop forming finger 51. The needle 61 penetrates the substrate 35 with the yarn 63. The yarn 63 is engaged by the bill 64 of a loop pile hook 65, thereby forming a yarn pile loop 60. The needle 61 is then raised above the substrate 35 and loop forming finger 51 and moved laterally across the loop forming finger 51, while the bill 64 is disengaged from the pile loop 60. The needle 61 is then lowered to again penetrate the substrate 35 which has been moved slightly through the tufting machine in the direction of the fabric feed 50, thereby forming a diagonally transverse loop stitch 62. In the process of raising and lowering the needle 61 some yarn is backrobbed from the pile loop 60 previously formed so that the resultant pile loop preferably has a low pile height as the pictured pile loops 66. If preferred for creating a double faced fabric or other purposes, a knife mechanism 97 (as shown in dashed line in FIG. 5) added, and typically the direction of the hooks 98 would be reversed, so that the pile loops 66 would be cut and the bottom surface would have a cut pile rather than loop pile surface. Also, if it is desired to make low loop stitches 62 on the face of the substrate, it is desirable to use loop forming fingers 51 that do not extend substantially rearward of the needles and will carry fewer stitches rather than the five stitches illustrated.
As shown in FIG. 12A, it is also possible to adjust the height and frequency of the loop stitches 62 on the face 44 of the substrate 35 to be nearly equal to the height and frequency of the pile loops 67 on the bottom 45 of the substrate 35 and thereby create a two-sided fabric 76. With such a two-sided fabric 76, the substrate 35 may be slightly offset from the center. Then as shown in FIG. 12B a first backing fabric 77 can be attached by latex or other suitable adhesive 79 to the top of the loop stitches 62 and a second backing fabric 78 can be similarly attached to the bottom of the pile loops 67, thereby sandwiching the two-sided fabric 76 between the first and second backing fabrics 77 and 78. The sandwiched two-sided fabric 76 is then sliced or cut apart approximately at the midpoint of the two-sided fabric 76 and the substrate is pulled away, leaving two separate fabrics of cut pile appearance consisting of a cut pile face yarn 73 and adhesive 79 on the surface of a backing fabric 77 and 78 shown in FIGS. 12C and 12D.
FIG. 6 illustrates a single row of needles 61 forming a fabric in the simple pattern shown. Each needle 61 has created a column of diagonally transverse loop stitches 62 over the loop forming fingers 51 of the loop forming plate 52.
Aside from the diagonally transverse loop stitch there are two additional types of stitches that can be formed by the present invention. A straight stitch can be formed by not laterally shifting the needle bar between stitches. In the case of a straight stitch, the yarn does not cross a loop forming finger 51 and is essentially similar to a back stitch formed on a conventional tufting machine. A transverse loop stitch or stitches may also be formed by stopping the fabric feed during the lateral displacement of the needles. Although this may be accomplished with cam driver mechanisms, it is desirable to have the fabric feed driven by at least one servo drive motor to allow for maximum flexibility.
FIG. 11 shows in diagrammatic form one such fabric feed mechanism. Illustrated is the substrate 35 passing under the front cloth roller 80 and over the front spike roll 81, through the tufting and stitching area, over the rear spike roll 83 where the face of the loop stitched fabric may be viewed by the machine operator, and under the rear cloth roller 84. The front spike roll 81 and rear spike roll 83 are connected respectively by axles 85 and 88 to the front servo drive motor 86 and rear servo drive motor 89. The control unit 91 electrically signals the servo drive motors 86 and 89 via cables 87 and 90 to stop or advance the substrate. The control unit 91 is also in communication with the needle drive (not pictured) via cable 92, the pattern control yarn feed 21 and 25 (shown in FIG. 1) via cable 93, and the pattern controlled needle bar positioner 36 (shown in FIG. 2) via cable 94. In this fashion, the control unit 91 can synchronize the yarn feed, fabric feed, and needle bar positioner with the needle drive to create a programmed pattern.
Unlike the usual back stitches which are tightly stretched across the substrate 35, the transverse and diagonally transverse loop stitches formed by the present tufting machine apparatus are formed over the loop forming fingers 51 of the loop forming plate 52. In this fashion, raised yarn loops are formed on the top surface 44 of the substrate 35. The height of the loops on the top surface 44 can be varied by changing the loop forming plate 52 to another with higher or lower loop forming fingers 51, or by adjusting the positioning of the loop forming plate 52 so that the loop forming fingers 51 are elevated above the substrate 35. FIGS. 1 and 4 show a mechanism for adjusting the height of the loop forming fingers 51. In FIG. 4, a crank 49 is connected by shaft 59 to a worm 58 engaging a wheel gear 46. The wheel gear 46 is mounted on a shaft 75. As shown in FIG. 1, shaft 75 is also mounted with gear 57 which engages the teeth 56 of a rack face 54 coupled to member 55. Thus turning the crank 49 will cause the member 55 to be raised or lowered and will correspondingly raise or lower the loop forming plate 52 and loop forming fingers 51.
FIG. 3 shows a single needle bar adapted to the present invention. The single needle bar machine is in many respects similar to the multiple needle bar machine described in FIG. 1 with the following exceptions: only front yarns 63 are fed through a yarn feed pattern control device 21, though apertures 19 in the yarn guide plate 20 and through a row of transversely spaced needles 61. The needles 61 are mounted in a single needle bar 27 which is in turn connected to front sliding rod 70 and rear sliding rod 71 slideably mounted in linear ball bearing assemblies 72 in a plurality of transversely spaced needle bar carriers 11. As with the multiple needle bar machine of FIG. 1, the needle bar carriers 11 are each connected to a push rod 16 adapted to be vertically driven by a conventional needle drive mechanism. A pattern controlled needle bar positioner mechanism, not pictured, connected to the front and rear sliding rods 70 and 71 can transversely shift the front and rear sliding rods 70 and 71 and thereby transversely shift the needle bar 27 and needles 61.
Four representative and novel fabrics that can be created according to the invention are shown in FIGS. 7-10. These range from the simpler fabrics shown in FIGS. 7 and 8 that can be created on a tufting machine with a single needle bar, to a more complex fabric in FIG. 9 that is created by a tufting machine with two needle bars, and a complex single needle bar fabric in FIG. 10 utilizing the fabric feed and yarn feed controls, in addition to laterally shifting the needle bar, to vary the pattern.
FIGS. 7A, 7B, and 7C show an example of a fabric that can be created by a tufting apparatus with the loop forming plate 52 and loop forming fingers 51. FIG. 7A shows the diagonally transverse loop stitches 62 formed on the top surface 44 of the substrate 35 by a simple lateral shift of the needles 61 over the adjacent loop forming finger 51. To create this fabric, threaded needles 61 (as shown in FIG. 5) are located between every second loop forming finger 51. FIG. 7B is an end view of one row of diagonally transverse loop stitches and low pile loops 66 formed by each needle 61. FIG. 7C shows the low pile loops 66 formed on the bottom surface 45 when the needles 61 penetrated the substrate 35.
The simple pattern of FIG. 7 is presented primarily for illustrative purposes. This fabric may not be desirable for commercial manufacture, because the columns of diagonally transverse loop stitches 62 are not adjacent or overlapping, and the substrate 35 is visible between the columns. FIG. 8A, though, shows a different pattern created according to the present invention by a single row of needles 61. In the pattern shown in 8A, each needle 61 is laterally shifted over three loop forming fingers 51 shown in dotted outline, and a needle 61 is located between each pair of loop forming fingers 51. As shown in the end view of a row of stitches in FIG. 8B, the diagonally transverse loop stitches 68 formed are interlocking and produce a fabric with superior coverage over the substrate 35.
FIG. 9A shows a sectional view of a fabric tufted by a tufting machine with two independently shiftable needle bars, such as the machine illustrated in FIG. 1. In FIG. 9A, the striped yarn is the rear yarn 22 and the solid yarn is the front yarn 18. The front yarn 18 is threaded in every front needle 14. Front needles 14 are placed between every second loop forming finger 51 and are laterally shifted over two loop forming fingers 51 to form each front diagonally transverse loop stitch 68. The rear yarn 22 is threaded in every second rear needle 15. Rear needles 15 are placed between every second loop forming finger 51 and are offset from the front needles. For each rear diagonally transverse loop stitch 69, the rear needles 15 are laterally shifted over four loop forming fingers 51. Because the rear needles 15 sew on the substrate 35 after the front needles 14, the rear diagonally transverse loop stitches 69 partially cover the underlying front diagonally transverse loop stitches 68. Some columns of the front diagonally transverse loop stitches 68 are totally overlapped by the rear diagonally transverse loop stitches 69 while other columns are partially overlapped or not covered at all. FIG. 9B shows an end view of a single row of front and rear diagonally transverse loop stitches, 68 and 69.
FIG. 10A shows a series of 11 stitches made according to the present invention on a substrate 35. Beginning from the needle carrying yarn penetrating the substrate at position A, the needle is raised, the fabric feed advances the substrate 35 in the feed direction 50, the needle bar positioner moves the needle two gauge units to the right and the needle is lowered through the substrate 35 at position B. This creates the first diagonally transverse loop stitch A-B. The operation is repeated except the needle bar positioner moves the needle only one gauge unit to the right and the needle is lowered through the substrate 35 at position C to create a second diagonally transverse loop stitch B-C.
For the third stitch C-D, the needle is raised and moved one gauge unit to the left, the fabric feed is stopped, and the needle is lowered through the substrate 35 at position D. This creates a transverse loop stitch. The fourth stitch D-E, and fifth stitch E-F are transverse loop stitches made identically to the third stitch C-D.
For the sixth stitch F-G, the needle is raised but is not laterally shifted, the fabric feed advances the substrate 35 and the needle is lowered through the substrate 35 at position G to create a straight stitch. The seventh stitch G-H is another straight stitch made in the same fashion as the sixth F-G.
For the eighth stitch H-I, the needle is raised and moved one gauge unit to the right, the fabric feed is stopped, and the needle is lowered through the substrate 35 at position I to create a transverse loop stitch. The ninth stitch I-J is also a transverse loop stitch but the needle is moved two gauge units to the right.
The tenth stitch J-K is a diagonally transverse loop stitch with the needle being raised and moved two gauge units to the left with the fabric feed advancing the substrate 35, and then the needle is lowered at position K. The eleventh stitch K-A is another diagonally transverse loop stitch but the needle is moved only one gauge unit to the left.
FIG. 10B shows the pattern made by a series of needles n executing two iterations of the pattern of FIG. 10A. The pattern made by needles n is complemented with the pattern made by needles n' which were alternatively spaced on the same needle bar. Because needles n and n' were on the same needle bar, those needles executed the same stitch pattern. However, in the case of needles n' on stitches C'-D', D'-E', E'-F', as well as stitches H'-I' and I'-J∝pattern control was directed not to allow sufficient yarn to the needles n' to form low pile loop stitches on the bottom of the substrate 35. Accordingly, when needles n' were raised up through the substrate 35, the backrobbing effect was sufficient to pull the yarn that penetrated the substrate 35 with needles n' back up to the face 44 of the substrate 35. Accordingly, stitches C'-D', D'-E' and E'-F' were not anchored by tufts penetrating the substrate 35 at either position D' or E', while stitches H'-I' and I'-J' were not anchored by a tuft penetrating the substrate 35 at position I'. Then the tufted fabric was processed by a shearing machine of conventional design and the loose untufted yarn from C' to F' and from H' to J' was cut away leaving the fabric as illustrated.
The stitching method described in connection with FIGS. 10A and 10B can be used both in the manufacture of fabrics directly on a plain substrate and for ornamental overtufting of existing fabrics.
Numerous advantages are inherent in the tufted fabrics illustrated in FIGS. 7 though 10. The transverse and diagonally transverse loop stitches give better coverage of substrate for a given weight of face yarn. Also, the substantially transverse orientation of the loop stitches prevents "grinning" or the exposure of the underlying substrate when the fabric is creased, as when a carpet is pulled over the edge of stair treads or the like. The resulting fabrics also have less resistance to a sliding traffic and higher abrasion resistance than conventional tufted fabrics. Fabrics made according to the present invention also have more drape or a greater tendency to lie flat, but are still easy to roll up due to the transverse or diagonally transverse alignment of a substantial number of stitches.
Numerous alterations of the structures and methods herein described will suggest themselves to those skilled in the art. It will be understood that the details and arrangements of the parts and yarns that have been described and illustrated in order to explain the nature of the invention are not to be construed as any limitation of the invention. All such alterations which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. | A single or multiple needle bar tufting machine is provided with loop forming fingers above the substrate or base fabric and by laterally shifting the needles during tufting, rows of loop stitches are formed over the loop forming fingers on the face of the substrate and rows of pile loops are formed on the back side. Methods are disclosed for utilizing this machine in connection with yarn feed pattern control devices, pattern control needle bar positioners, a controllable fabric feed, to create a variety of novel fabrics and fabrics simulating patterns heretofore only made on looms and knitting machines. The resulting fabrics offer many advantages including lower stitch rates, better substrate coverage, less resistance to sliding traffic, increased abrasion resistance, and improved draping characteristics. | 3 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.